Clutch Lever Engagement

[Winterhawk]

Just completed a carburetor rebuild. Biked started right up on 1st try. Pulled the clutch lever in to put her in 1st gear, lever would only engage about 3/4 of the way fully in. It felt like something was blocking the lever? Checked hose and lever everything seems fine. Any suggestions? Air in the system? Master cylinder spring/piston? Bike did engage 1st gear no problem a bit hard to shift back to neutral. Any suggestions?

[WintrSol]

Just completed a carburetor rebuild. Biked started right up on 1st try. Pulled the clutch lever in to put her in 1st gear, lever would only engage about 3/4 of the way fully in. It felt like something was blocking the lever? Checked hose and lever everything seems fine. Any suggestions? Air in the system? Master cylinder spring/piston? Bike did engage 1st gear no problem a bit hard to shift back to neutral. Any suggestions?

Do you mean to say, you didn't feel the pressure build enough to disengage the clutch until the lever was pulled that far? If that's what you mean, then you have air in the system, very possibly at the banjo fitting at the master cylinder. Flush and bleed the system (should be done every year or two, anyway), but have the stand on a block that holds the bike near level, and turn the bars to the right, so the banjo is lower than the rest of the MC. After bleeding, pull the lever in slowly (count of 10), hold a few seconds, then let it snap back; this will force air in the banjo back into the MC, where is will be released into the reservoir. Repeat the slow pull, hold, and snap back a few times, to get most of the air out. You can do with with the cap on, so it doesn't splash fluid where it can harm paint.

[Winterhawk]

I'll try that. Normally I can pull the clutch lever all the way in until it touches the handle grip. Now it stops before it gets there. My question is what is preventing the lever from being fully engaged?

[Pete]

Make sure the brass barrel in the clutch lever is installed correctly and not galled.

[WintrSol]

I'll try that. Normally I can pull the clutch lever all the way in until it touches the handle grip. Now it stops before it gets there. My question is what is preventing the lever from being fully engaged?

OK, I didn't get that the lever actually stopped moving before it reached the grip. That's a mechanical problem at the lever or master cylinder. You'll have to check the hardware, like the barrel and other parts, to see what is blocking the lever. If it's nothing external to the MC, you may need to open it up, and look for something out of place.

[Winterhawk]

Thanks! Took the lever off cleaned the external piston and lever reassembled little improvement. MC next step.

[Brewer]

If the master cylinder, lever, bushing, plunger, and pivot point are all correct....

It is possible one or more rivets in the clutch pack are in the way of correct operation. Someone with a better technical description should chime in.

I had this occur and a local shop fixed it for me.

[Valkpilot]

If the master cylinder, lever, bushing, plunger, and pivot point are all correct....

It is possible one or more rivets in the clutch pack are in the way of correct operation. Someone with a better technical description should chime in.

I had this occur and a local shop fixed it for me.

What he said.

When I had that symptom, it was the rivets in the clutch damper plate failing: http://www.valkyrieforum.com/bbs/index.php/topic,20870.0.html

[Hook#3287]

Did the clutch work correctly before the carburetor work?

[Ricky-D]

Yep! Rivets in the clutch damper plate. Toasted!

All that downshifting sure saved the brakes tho.

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[Winterhawk]

The the clutch worked fine before the carb rebuild. The bike only has 39k on it and it has been maintained with care.