Clutch problems. Need help - Kawasaki Vulcan Forum : Vulcan Forums
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post #1 of 16 (permalink) Old 07-06-2019, 02:34 AM Thread Starter
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Clutch problems

I have a 99 vulcan 1500 . I had slippage with the clutch and i didnt ride the bike for almost 3 years .
Finally bought the parts and took it all apart and got it back together torqued and all . Then i tried to put back on the clutch cover plate and noticed the push rod which attaches to some bearings and washers before the cover plate is pushed out and i cant get it to move . It stick out about 1/4 of an inch or more and its preventing the cover plate from going back on .
Really dont know what i did wrong . And also the clutch lever is as stiff as a board . Wont budge . Not sure if this happened after the reassembley??. Took it all back apart to see if i missed something but didnt notice anything . Im stumped !!??? Any help would be appreciated.
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post #2 of 16 (permalink) Old 07-06-2019, 08:42 AM Thread Starter
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Clutch problems. Need help

I have a 99 vulcan 1500 . I had slippage with the clutch and i didnt ride the bike for almost 3 years . Finally bought the parts and took it all apart and got it back together torqued and all . Then i tried to put back on the clutch cover plate and noticed the push rod which attaches to some bearings and washers before the cover plate is pushed out and i cant get it to move . Really dont know what i did wrong . And also the clutch lever is as stiff as a board . Wont budge . Not sure if this happened after the reassemble ??. Took it all back apart to see if i missed something but didnt notice anything . Im stumped !!??? Any help would be appreciated.
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post #3 of 16 (permalink) Old 07-06-2019, 08:43 AM Thread Starter
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Its a Classic btw
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post #4 of 16 (permalink) Old 07-06-2019, 09:07 AM
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Thatís where I am at this morning to. Exact same thing
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post #5 of 16 (permalink) Old 07-06-2019, 09:24 AM Thread Starter
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Yea its kinda weird and im pretty sure we arent the only ones that this has happend to.
Hopefully we get some positive assistance soon. Keep me posted if you find out anything . Thanks
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post #6 of 16 (permalink) Old 07-06-2019, 09:29 AM
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Look at post under urs, "friction plate change.
My comment regarding my 1991 clutch spring replacement , hope it helps
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post #7 of 16 (permalink) Old 07-06-2019, 03:43 PM
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Did you get it working? My problem was not putting that last final aluminium keeper on first. And then the clutch spring.
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post #8 of 16 (permalink) Old 07-06-2019, 04:41 PM
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Check the 1500 section.

There have been a couple threads regarding this exact issue I remember seeing there, pretty recently too.
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post #9 of 16 (permalink) Old 07-06-2019, 08:54 PM Thread Starter
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Ok ill check it out . Thanks
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post #10 of 16 (permalink) Old 07-06-2019, 08:56 PM
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If your clutch get hards as rock when pumped, then your problem lies between the slave cylinder and clutch basket/clutch spring. It is possible that the slave cylinder is moving but then freezing, but it is highly unlikely. When you pull the clutch handle the master cylinder feeds the fluid to the slave cylinder. The spring assisted piston in the slave cylinder moves the clutch rod 1mm (just over 1/3 of an inch) This moves the clutch basket that 1mm to allow the friction plates to turn freely until the pressure is released again, closing the gap. What is happening to you is when the slave cylinder piston is extending it is either reaching the end of its limit without having pushed the push rod or it has pushed the push rod and the rod is running into a brick wall which is not allowing it to move further and complete the 1mm movement to release the clutch basket. So something from the slave cylinder to the nut holding on the clutch basket is hosed. When mine did that I had forgotten to tie down the clutch handle before I started so when I re-assembled my clutch I pushed the push rod in (because you can't get the clutch spring on properly if the push rod is extended), but by the time I got to re-seating the clutch spring and tightening down bolt, the rod had moved back out. I tightened it up but because the rod wasn't seated properly I didn't get it tight enough. As soon as started the engine the centrifugal force loosened the clutch spring allowing the rod to extend far enough that my slave cylinder would hit its end and freeze up just like yours is doing. Pulled it apart again and found the bolt was loose and realized my mistake. The second time I tied down the clutch handle so that the pressure would not extend the rod all the way and then reseated everything and tightened the bolt down again to specs. She has been fine ever since about 3 years now. So that is where you have to look. cylinder, rod, clutch basket, spring and all the other little springs. Properly torqued and seated bolt holding the whole thing together. Hope this helps in some way, but that is where you will find your problem. Apologies for the layman detail but I have no way of knowing what or how much knowledge you have so thought I would just add it in, in case it might help in some way. P.S. The only other thing that can cause your problem is if the fluid is not moving from the master to slave cylinder. Just pull the slave cylinder off and watch it to make sure it is extending properly from the master cylinder.
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