Hard Clutch Lever

[Gearhead24]

Hello,

I just got the engine put back together and everything fully installed after a hydrolock. When I took off my clutch slave cylinder I noticed a lot of dried brake fluid on the inside which explained why the clutch was getting softer and softer. I cleaned it all out and made sure it was clear inside. Bled the clutch with new fluid and strapped the handle all the way down overnight to get the microbubbles. After I finished installing everything I rolled the bike to the street thinking I could give it a test ride. The clutch lever was insanely hard to the point where I couldn't pull it half way, if I pulled the lever as hard as I possibly can and pushed the shifter down the bike will just stall. In the manual it says a hard lever is a sticking or clogged hydraulic system and one of the causes for the clutch not disengaging is also a sticking hydraulic system. Plates are not warped, I put a full gallon of oil in, and have been continuously filling it with dot 4 fluid. If it is a sticking or clogged system how do you go about remedying it, the manual does not show that.

[da prez]

  Clutch pivot pin may need some love. Remove pin , if good , no worn area ,re-lube and try.  There is an aftermarket pin for a lot less than Honda. I do not remember the number.  If pin is good , loosen the bleeder and try for movement.  Hoses have been known to fail internally. If it is a hose , I have one if you can't find one.

                                        da prez

[Gearhead24]

thanks, I'll give that a shot. Never had to deal with a hydraulic clutch system besides bleeding it so the internal pieces are a bit new to me. Just to make sure I was looking at the exploded diagram of the master cylinder and only found one pivot bolt for the handle itself. Not sure if that is what you're referring to but I'll give that a shot and if that doesn't work I'll take apart the master cylinder completely for a clean

[Valker]

I think he is speaking of part #2 on a "Clutch Master Cylinder" parts fische diagram. BUSH 22885-MB0-006

[Gearhead24]

Just got my master cylinder removed and mostly disassembled. Was dirty in there but the plunger still moves smoothly so there’s that. The bush does look like it’s seen better days, although maybe a brass brush and some red axle grease might help it out. When I put the assembly together the handle moves easily and I can feel the slight pressure from the open cylinder so maybe the issue lies further down in the slave cylinder  Wish I could post a picture of the bush but the file size is too large apparently

[-mike-]

@da Prez: Suzuki part ist the one you mentioned:

Part No.  59892-08A00-000

-mike-

[Gearhead24]

When I put the clutch back together there were a couple of questionable things. First off is the directional washer, any lettering on it had been taken off so I placed it how I think it goes with the angle of the washer being outwards. The bike will go into gear so I think that washer is right. The only other thing that had me worried was a pushrod that goes into the main shaft. On the parts diagram it shows parts #16 and #10 going through the center bearing of the lifter plate, however those two parts don’t show up on the list. Instead, the parts that I do have are #15 and #9 which seem to be in a little box off to the side of this diagram. I put those two pieces through the center bearing of the lifter plate but now I’m thinking that’s not where they go
PS, I can’t upload the pic of the diagram but I’m looking at the clutch diagram on Honda’s parts finder

[Gearhead24]

I think I found my issue. Got the slave cylinder out and the inside piston was frozen. Guess I didn’t clean it all the way or maybe cleaned it too much. I can pull the piston out with a hook, but when I push it in it does not spring back up. Could this be a matter of further cleaning and oiling the piston or do I absolutely need a new cylinder
EDIT:
After going over the diagrams online and in the manual I found that I put the lifter rod in wrong. I put pieces 22366-MN5-000 (piece, clutch end) and 22851-MN5-010 (rod, clutch lifter) into each other and into the mainshaft. I was a little discombobulated during the removal of everything so I didn't exactly remember where it all went. However, I seem to be missing the clutch lifter piece shown in the manual. The piece that sits over the ball bearing of the lifter plate. I cannot find that piece in any parts fische nor anywhere online. Currently the ball bearing on the lifter plate has nothing in the middle of it. I will reinstall the lifer rod into the slave cylinder but will that solve my problem? If I do that I feel like the lifter rod will just push itself through the lifter plate and the clutch still won't disengage. Is that rod meant to push on something or does it use any oil that's in the passageway to push the clutch?

[da prez]

  Mike , THANK YOU. I will enter it in my personal work book.

                                   da prez