Clutch problems. I think.

[johnny767]

Hello All,

I have a 1998 Kawasaki Voyager XII (ZG1200-B12) and yesterday I noticed that the clutch lever started to engage almost as soon as I started to release it. Then when I got on my bike to ride again I started it in neutral with the clutch lever all the way in and the bike took off like the clutch wasn't disengaged at all.
I love repairing things on my own but need help. Where should I start or has anyone had this problem?
Would it be the clutch master cylinder if it happened this fast or do you think I'll have to replace the clutch or parts of it? Is there any good web sites that I can purchase parts for my bike. Ok, I just tired to bleed the clutch master cylinder and it wouldn't push any fluid or air into the bottle of brake fluid. Any suggestions on where I can get a rebuilt master cylinder or a good web site for parts.

Thank you all very much.

You all and ride safe.
johnny767

[chevyman1]

I would flush it out and chance the fluid and see if that helps.
If the fluid that's in there is old it could be more like jelly then fluid.

[triton28]

Johnny67;
In continuing Chevyman 1's remedy, check the 2 small holes in the floor of the clutch master cylinder, especially the rear, supply one (farthest from the banjo bolt), to ensure they are clear and allowing the fluid to enter and exit the bore of the master cylinder.
If there is NO running/dribbling out leakage evident at either the master or slave cylinders, it sounds as though the fluid is not getting into the bore to be pumped to the slave cylinder and thereby operate the clutch rod.
So the clutch lever does in fact pull smoothly in to the handlebar as intended, correct? Or is it stiff or hard to pull in?
Sometimes with the 2 holes, if the front hole, (return smaller hole), is blocked, the clutch plates can get pumped up hard and be disengaged with slippage as the primary symptom.
However if it is the rear hole which is blocked, or if there is air in the system, not enough pressure will be exerted on the plates and the symptom is clutch dragging, which sounds to me to be your problem. Definitely as Chevyman 1 said, change that fluid.
Just some thoughts which may or may not help.
Dave
Dave

[Bill O]

I've seen this symptom on a few older Voyagers. What has happened is your piston cup in the clutch master has worn down and developed a blow-by of the hydrolic (sp) fluid so the clutch lever does not keep the clutch disengaged. When the pressure bleeds by the master piston in the clutch master cylinder the clutch hub re-engages the plates and the bike wants to take off if in gear. A repair kit is available for about $30-40 to completely reuild the Clutch Master Cylinder.

Take care not to order the repair kit for the front brake Master Cylinder. They look similar but are not the same.

Bill O

[Avidrider62]

I rebuild mine, bought the nice needle nose pliers to get to the snap ring ofi n the master, not always needing the kit. When re-assembling the clutch master, I used brake fluid and 600 grit or higher to sand the bore to rid of the hardened scale. Same at the slave. Like mentioned, blow by of the fluid internal.

[bikerking.biz]

If all the other mentioned fixes/checks doesn't work, you may want to check the "star" washers in the clutch as one of more may be broke. I think the '98's had those. They break and the pieces will lodge between the clutch plates and cause drag and shifting problems.