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Dano98 |
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Dano98 Derestricted Danger
Joined: 21 May 2024 Karma :
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Posted: 21:31 - 21 May 2024 Post subject: Intruder 1500 clutch issues (never ending story) |
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Hi. Im in desperate need of help. I have recently bought a Intruder 1500 (year 2000). Everything was fine but suddenly clutch start to slips after 50km of ride. It was slipping for apx 5 mins and after that it was good and another 180km was without any issues. Next day I went for a ride and boom, clutch start to slipps after 5 mins of ride. I went home, cleaned the master cylinder (it was full of nasty gunk), changed the fluid, bleed it precisely (the system was full of that nasty gunk too). Not helped. That little tiny hole in master is good, it isn't blocked, because when I do reverse bleeding, the fluid sprays out of it. I changed the clutch springs for EBC which are 15% stronger that OEM. Not helped (clutch plates are good I measured them). Then I take out the slave cylinder from engine, put the cover down from it and man! The place was full of dirt and nasty shit. I cleaned it out, then i pushed the piston all the way in, cleaned surroundings of piston, put it all together. ET voila, no slipping at all! I made 120km that day without single issue. BUT. Two days later I went for a ride and after 20km I noticed, when I was turning into gas station, that my clutch lever is very soft. It hasn't that resistance as it have to. But no problems, no slipping and gears were going fine. Then I made another 20kms, then i stopped on the side of the road, (motor was on). After few mins I put gear bc I wanted to go and - here we go again - clutch started to slipps!! Fu**!! After that I stopped on the parking lot, turned off the engine, made some call, during which I pumped clutch lever several times. After 5 mins I started motor, and suddenly bike was going fine, no clutch slipping at all. After few kms I went to the shop for something, turned off the bike and after another few minutes when I came back from the shop the clutch again started to slipps. Oil and filter is new - Motul 5100, 10W40.
Where the f… can be the problem??? I cannot figure it out and Im going out of the options. One day it is good, no issues and another day everything is fuc*ed again… |
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stinkwheel |
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stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
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Posted: 23:21 - 21 May 2024 Post subject: |
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Did you change the seals in the slave cylinder? Might be worth popping it apart, giving it a good clean and reassembling with new seals. There's a return spring in there too on a lot of bikes and that can get corroded and sticky
Not sure of your exact setup but how's the pushrod? I know on other bikes, the clutch pushrod can get a lot of corrosion on it which makes it stick against the seals. ____________________ “Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles. |
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Nobby the Bastard |
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Nobby the Bastard Harley Gaydar
Joined: 16 Aug 2013 Karma :
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Dano98 |
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Dano98 Derestricted Danger
Joined: 21 May 2024 Karma :
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stinkwheel |
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stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
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Posted: 05:42 - 22 May 2024 Post subject: |
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When you say the slave cylinder was cleaned, do you mean you pumped the piston out and removed it for cleaning and inspection, removed the seals, cleaned the inside of the cylinder including groove behind the seals, fitted new seals then re-bled the system with new fluid?
So there was mud-like material contaminating the hydraulic fluid? ____________________ “Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles. |
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Dano98 |
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Dano98 Derestricted Danger
Joined: 21 May 2024 Karma :
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stinkwheel |
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stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
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Posted: 13:09 - 22 May 2024 Post subject: |
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You do have to wonder if there's something up with the hose. The only mud-like stuff that could be there is damaged seals in one of the cylinders or damaged hose lining.
I'd be tempted to throw a new hose on there too while you're doing the rebuild.
Also left of field suggestion, does it have a standard clutch lever? I've seen people fit aftermarket shorty brake levers to bikes which didn't allow the master cylinder piston to return fully which eventually pumped up the hydraulics and cooked their brakes. Also seen (done ) a lever protector doing similar. No reason the same thing couldn't happen with a hydraulic clutch. ____________________ “Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles. |
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Dano98 |
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Dano98 Derestricted Danger
Joined: 21 May 2024 Karma :
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stinkwheel |
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stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
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Posted: 15:25 - 22 May 2024 Post subject: |
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Well, there's the clutch end but given it sometimes slips and sometimes doesn't, that's less likey. It sounds like something is hanging up and not releasing the stack properly from what you describe. ____________________ “Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles. |
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Dano98 |
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Dano98 Derestricted Danger
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Robby |
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Robby Dirty Old Man
Joined: 16 May 2002 Karma :
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Nobby the Bastard |
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Nobby the Bastard Harley Gaydar
Joined: 16 Aug 2013 Karma :
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blurredman |
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blurredman World Chat Champion
Joined: 18 Sep 2010 Karma :
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Posted: 23:07 - 24 May 2024 Post subject: |
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Nobby the Bastard wrote: | Robby wrote: | It's 24 years old. That could be long enough for the hydraulic line to fail internally, and act like a one way valve. Not something I've seen personally, but I keep hearing about it recently.
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Ye, thats a thing. It happened with my brothers bike's front brake and we both poo-pooed those who suggested it until I released the pressure using the bleed nipple and then found it locked again as soon as the level was pulled.
Fixed by replacing the pipes. |
Has happened on one of my cars too. Even just a 10 year old flexi line swelled so much internally the drum was locking. When I cut the flexi hose open I couldn't see any hole! ____________________ CBT: 12/06/10, Theory: 22/09/10, Module 1: 09/11/10, Module 2: 19/01/11
Past: 1991 Honda CG125BR-J, 1992 (1980) Honda XL125S, 1996 Kawasaki GPZ500S.
Current: 1973 MZ ES250/2 - 17k, 1979 Suzuki TS185ER - 9k, 1979 MZ TS150 - 9k, 1981 Honda CX500B - 91k, 1987 MZ ETZ250 (295cc) - 38k, 1989 MZ ETZ251 - 50k. |
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pdg |
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pdg World Chat Champion
Joined: 15 Sep 2012 Karma :
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Dano98 |
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Dano98 Derestricted Danger
Joined: 21 May 2024 Karma :
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Posted: 09:02 - 25 May 2024 Post subject: |
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Some update. Yesterday I repaired the master and slave cylinders with repair kits with brand new gaskets and so. I flushed the hose and checked its rubber part and its steel part. Hose looks good, I will change it in few days anyway, but now it looks good. I tried to blow in it with my mouth and I cannot feel any resistance or flaws. I put it all together, bleeded it toroughly and I mounted the slave cylinder on the engine with some washers (only for control reason), so that there was a little gap, enough for me to clearly see the pushrod. As I was squeezing the clutch lever, the pushrod go in and out really smoothly, with no issues. And it goes back all the way it goes in, so it looks, that the hydraulic system is 100% functional. I will try it today when I come from work. If it will be still slipping, then it must be the clutch itself. |
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Dano98 |
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Dano98 Derestricted Danger
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pdg |
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pdg World Chat Champion
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Dano98 |
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Dano98 Derestricted Danger
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stinkwheel |
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stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
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Posted: 22:20 - 25 May 2024 Post subject: |
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You checked the thickness of the plates but are they straight? Get the plains on a sheet of glass and see if they rock or if you can get a feeler guage under them. ____________________ “Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles. |
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pdg |
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pdg World Chat Champion
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Dano98 |
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Dano98 Derestricted Danger
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Dano98 |
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Dano98 Derestricted Danger
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Posted: 21:43 - 01 Jun 2024 Post subject: |
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