Chapter M-2's Technical Corner

Howard Halasz's May 2008 Technical Article

Clutch Maintenance

 

Howard,

 

I was noticing that I had very little clutch, so I took my '96 SE Gold Wing to my buddy's. We bled the clutch and replaced the DOT4 fluid. After doing that I had no clutch! We bled the fluid over and over and still no clutch! I replaced the clutch master and the slave cylinder. As of one hour ago still no clutch!! I've read several articles in the Wing World about changing fluid - went right by them. Could it be the push rod in the clutch or a clutch problem? Maybe, the rubber clutch line expanded? Any advice would help. If you would, please, return this e-mail as soon as possible. Thank for your help,

 

John,

 

Read the following and follow our instructions carefully:

 

After you put the fluid in your clutch master cylinder, you will need to bleed the master cylinder first. Before you begin this procedure, protect your plastic body parts directly below your clutch master cylinder by covering them with plenty of cloth towels, blankets, or whatever rags you have handy. DOT 4 brake fluid is extremely damaging to paint and plastic body parts.

 

Now let's begin by putting the Gold Wing on its center stand. You might need to adjust the riding position of your handlebar to make sure that the fluid level in the reservoir is parallel to the top edges of the reservoir. Pull back the rubber boot from the banjo bolt fitting where the rubber hose from the master cylinder fastens to the master cylinder. Using a 12 mm socket wrench or a 12 mm box end wrench, loosen, but do not remove, the banjo bolt. Squeeze the clutch lever. Now slightly snug up the bolt while the clutch lever is squeezed. Now release the clutch lever.

 

Again, using your 12 mm socket wrench or a 12 mm box end wrench, loosen, but do not remove, the banjo bolt. Squeeze the clutch lever. Now slightly snug up the bolt while the clutch lever is squeezed. Now release the clutch lever. Check the fluid level in the reservoir.

 

Repeat this procedure several times until you no longer see or hear air escaping from the banjo bolt fitting. Things are starting to get a little messy from leaking brake fluid by now, so make sure that any spilled fluid is washed away with clean water and a sponge.

 

When the clutch lever starts feeling like it is working properly, you can tighten the banjo bolt fitting.

 

Now you can bleed the slave cylinder like you did before you bled the master cylinder.

 

Howard Halasz, Technical Coordinator

Texas Chapter M-2

Spring, Texas