Thursday, 3 January 2019

Fixing old/unused clutch that won't disengage


Hello Reddit, new to motorcycle repairs.​I have a 2003 Suzuki Intruder VS800GL that was purchased new in 2003. It only has 785 miles on it, but has not ran since 2007. I did a carburetor rebuild (on both), replaced the fuel pump because it was dead, and got a new battery. The bike turns on however as soon as you try shifting into 1st the bike lurches forwards, stalls, and dies all within a single second or so. Took it to a mechanic who suggested replacing clutch fluid (hydraulic based), so I had him do that and it did not fix the issue. He then suggested replacing the clutch slave system, to which I personally did - however I am unsure if I correctly re-bled the system and/or the issue is somewhere else. The clutch lever feels softer than the front break lever (which is also hydraulic based). I do not know if this is supposed to be the case or not. If I look at the clutch slave cylinder I can see it pulsing as I pull the lever in, it moves maybe 0.25" at most, probably a little less.​I also took the crankcase cover off and replaced the clutch discs (the ones with metal-infused cork or whatever for creating friction) and replaced the engine oil (SAE 10w-40).​TLDR: Bike turns on, cannot shift into 1st, clutch is not disengaging (replaced slave cylinder, bled it, and replaced clutch discs) via /r/motorcycles https://www.reddit.com/r/motorcycles/comments/acdezk/fixing_oldunused_clutch_that_wont_disengage/?utm_source=ifttt

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