Clutch Problems

Discussion in 'Thumpers' started by 1stworks, Apr 17, 2006.

  1. 1stworks

    1stworks dude

    Joined:
    Jun 25, 2004
    Oddometer:
    1,616
    Location:
    south side
    So Iam Going Down The The Road Above 65 Mph
    And I Loose My Clutch?i Pull The Handle And No Clutch?
    Iam Taking It For Some Warenty Work And Need An Heads
    Up On The Clutch.i Ran It Low But Top It Off And It Works
    Fine.i Think Iam Loosing Fluid?has Anyone Had This Problem?
    I Have 1 Month Left On The Warranty And Hope To
    Get This Fixed.i Also Have A Torn Boot From Carb To Air Box.
    And I Want Them To Check My Fan.

    IT IS AN 03 640 ADV

    Thanks

    Firstworks
    #1
  2. ChrisC

    ChrisC Amal sex?

    Joined:
    Feb 25, 2003
    Oddometer:
    6,320
    Location:
    Prescott, Arizona USA Earth
    I am travelling at highway speed (65+ mph) and I lose my clutch. The lever goes to the bar with no effect. I am going to my dealer for warranty work and would like to informed on how the clutch works before I go in. It had been low on hydraulic fluid, but when topped off it seemed OK. I may have a leak. Has anybody else experienced this? I have a month of warranty remaining and would like to get this addressed. As an aside, I also have a torn carb/airbox boot and I may have a cooling fan problem.

    repaired (the caps key thing made my brain hurt :cry )
    #2
  3. 1stworks

    1stworks dude

    Joined:
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    Oddometer:
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    Location:
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    Sorry for my poor grammer.
    Someone help.


    firstworks
    #3
  4. ChrisC

    ChrisC Amal sex?

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    Oddometer:
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    OK, fair enough.

    Does the clutch lever go to the bar with no resistance and zero clutch action? The reservoir is full, yes? Have you tried bleeding the slave cylinder?
    #4
  5. 1stworks

    1stworks dude

    Joined:
    Jun 25, 2004
    Oddometer:
    1,616
    Location:
    south side
    Lever goes to bar w/ no resistance.
    Zero clutch and i did not try to bleed.
    The res. is full.I ran it low but topped it off and it was ok for
    one month.I dont see any leaks.
    Thanks for any help.

    firstworks
    #5
  6. creeper

    creeper Still alive...

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    Puget Sound
    Hummmm....

    Could be air in the line... lots of air. Or, it could be a faulty master or slave cylinder, or a major leak (which would be a faulty slave cylinder) inside the engine.

    Just out of curiosity, what did you put in the reservior when you topped it off?

    Thats all I got.
    C
    #6
  7. 1stworks

    1stworks dude

    Joined:
    Jun 25, 2004
    Oddometer:
    1,616
    Location:
    south side
    I Used Mineral Oil Like It Says To Use.
    Why Does It Work When I Filled It Up.
    If There Was Air In System Would The Clutch Come Back?
    It Looks Like The Slave Is Attached To Outside Of Case?
    What Will I See Inside The Case?

    Thanks For Your Help
    Firstworks
    #7
  8. creeper

    creeper Still alive...

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    You didn't say that it works when you fill it up, you said you topped it off a month ago and it was OK 'till now.

    It might come back, as the system is designed to self-bleed... assuming the master cylinder is higher than the hose.

    The slave is outside, but attached to the case... a small leak may not be readily visible.

    C
    #8
  9. Esteban

    Esteban Banned

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    Jun 7, 2004
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    5,799
    Location:
    Above Golden

    I am travelling at highway speed (65+ mph) and I lose my clutch. The lever goes to the bar with no effect. I am going to my dealer for warranty work and would like to informed on how the clutch works before I go in. It had been low on hydraulic fluid, but when topped off it seemed OK. I may have a leak. Has anybody else experienced this? I have a month of warranty remaining and would like to get this addressed. As an aside, I also have a torn carb/airbox boot and I may have a cooling fan problem.

    Repaired the orange on black, made my eyes hurt. That should just about do it, now where were we ?

    Esteban
    #9
  10. acupuncture4u

    acupuncture4u Freedom by knobbies

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    I was kinda enjoying the orange. KTM getting in the blood I guess...
    #10
  11. Max Kool

    Max Kool Xtankteam™

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    Jan 19, 2004
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    3,451
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    Los Angeles
    You filled it up with MINERAL OIL??? Like in "mineral engine oil"??

    I'd say bleed that sucker thouroghly. Flush it with at least half a quart of DOT 4 (or 5.1) to remove it. I 've never heard of using engine oil in a hydraulic clutch system.

    But the fact that you had to refill it should have made some sirens and alarm bells ring in the first place. The volume of the master cylinder should be more that enough to compensate for clutch wear, won't it?

    I suspect the slave cylinder is leaking.
    #11
  12. Yellow Pig

    Yellow Pig Allergic to asphalt!

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    Location:
    Kalifornia
    No, No!

    It's a Magura hydraulic clutch and uses a mineral biodegradable clutch oil, kind of like the stuff in mountainbike brakes.
    #12
  13. huskychopper

    huskychopper Ride Fast, Take Chances!

    Joined:
    Aug 30, 2005
    Oddometer:
    71
    Location:
    The foot of the Rockies
    O-ring in either the master cylinder or slave cylinder goes out!
    #13
  14. enduro-ince

    enduro-ince dirtslave

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    Placerville Co.
    Anybody rebuild their slave cylinder with a rebuild kit?
    Easy enough for a mechanical moron to do?
    #14
  15. cevquit

    cevquit maphead

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    NO NO NO NO, Magura products use a mineral oil NOT BRAKE FLUID.
    Brake fluid will kill your Magura Hydraulic clutch. Check for blockages in the cranckcase or head breather vent. If they are blocked, engine case pressure will push on the piston of the slave at higher rpm. The slave rebuild is a complete set up, piston and cylinder, it bolts to the outside of the case.The slave gets quite a bit of wear and replacing the oring will fix it for a short while, but the worn area of the slave will cause the new oring to wear faster, a couple month fix at best.There are a couple of nooks and crannys in the slave that take quite a bit of bleeding to get all of the air out. It took three bleeds to get all the air out of my friends clutch on his 03.
    On a funny related side note, always check your fluid before using. When we went to baja last month, my buddy, who has been going through the whole worn clutch thing, filled his clutch with fluid.After afew days of riding it needed a topping off, so when he takes off the cover the master is full of goo,WTF.So he goes to the oil box gets the white bottle of magura blood, when he opens it it hits him, its not magura blood but window washing soap. The two come in exactly the same bottle, and the labels had come off of both. Rode for 500 miles with soap in his clucth.
    #15
  16. RedDread

    RedDread What I can While I can.

    Joined:
    Mar 14, 2007
    Oddometer:
    32
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    Idaho


    I hope you clutch kings sleuthed this out and have some advice. I am having a remarkably similar problem with my 03 adventure. The issue manifested as what I would think is a slow leak that I could not pin point. As a result I have replaced the the clutch master cylinder, pipe, release gasket, clutch piston and o-ring. The only thing not replaced is the cylinder itself. Yet it still loses pressure to the point that the lever is dead inside 30 miles. Am I missing something or do I need to keep chasing the problem and replace the cylinder?:baldy
    #16
  17. meat popsicle

    meat popsicle Ignostic

    Joined:
    Feb 9, 2004
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    14,355
    Location:
    Circumlocution Office of Little Dorrit
    RedDread,

    Sorry but I am not a hydraulic clutch troubleshooter. I can try and help guide you through some of the info and ask some stoopid questions :D

    Did you go through cevquit's advice on the previous page?

    When you do your setup there is quite a bit of info from Creeper here:
    http://www.advrider.com/forums/showthread.php?t=233283

    If you have done everything else correctly then that last piece of the puzzle is a likely candidate.
    #17
  18. Ruffus

    Ruffus Dirty Old Mudder

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    Fort Erie,Ontario
    Does it only happen at higher highway speeds? does it come back right after you shut it off?

    I had a similar issue on my Husky (Similar style hydro clutch), but only had a couple hundred miles on it, I tried all the regular checks, bled it 3 times, not loosing fluid at all. Someone mentioned to check the crank case evac hose, sure enough, mine was pinched. I rerouted it & problem solved. His reasoning was that pressure built up in the crank case pushing the slave out, or somehting like that, my memory fails me. Might sound like a long shot, but its a free check
    #18
  19. jstuma

    jstuma n00b

    Joined:
    Mar 28, 2008
    Oddometer:
    2
    Hi, new to the forum... are there differences in the clutch slaves? Do some not have a "throw out" bearing. What I mean is, do some just have a piston that pushes the rod, the rod rides in a hole on the piston or should all have a bearing. I am trying to hunt down a clutch noise and it is very much like a throwout bearing but my dealer says a 2002 R1150R does not have a bearing...? appreciate any help
    #19
  20. meat popsicle

    meat popsicle Ignostic

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    Location:
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    Hi jstuma,

    so you have a BMW R1150R eh? You might find someone in Thumpers (single cylinder bikes) that has or knows that bike (or is a clutch slave wiz) but you might have better luck in the Beasts or GSpot forums. Good luck :beer
    #20