98' clutch releases, even when held down

[kevinr]

Just picked up a Voyager today. There appears to be an issue with the clutch. When I'm coming to a stop and pull the clutch lever all the way, it disengages fine at first, but if I hold it more than 15 seconds it will reengage as if I'm releasing it. I bought some brake fluid, and plan on doing a flush, but I wanted to post here and make sure I'm on the right track or if there were any other suggestions.

Thanks.

[triton28]

Definitely change the fluid and bleed the system if you can not attest as to the age of the fluid in the system. You may find that the problem disappears. If the problem persists I would say that in theory the brake fluid is leaking back past the rubber sealing device/s from a pressurized condition to a static condition. The master cylinder may be in need of a rebuild kit provided the cylinder bore isn't deeply scored with longitudinal lines. Or the slave cylinder piston may be corroded/pitted from moisture, brake fluid being hygroscopic.
Too many riders overlook the importance of regularly changing the brake fluids and water collects invisibly "in solution" and sometimes even visibly "in suspension" leading to corrosion and severe pitting.
Generally it is the master cylinder where problems occur as the rubber seals do the traveling in the bore whereas in the slave it is the piston which moves inside the seals.
Hopefully flushing and changing the fluid works for you but if not, the worst part of rebuilding either cylinder is finding that long long deep special circlip tool/plier to get at the master cylinder circlip. Also ensure the tiny, forward most, return port on the bottom of the master cylinder is not corroded shut otherwise you could develop, which is different from what you have now, a clutch which does not engage when letting the lever out, as with the return port plugged the fluid can not release into the body of the reservoir and the clutch remains disengaged.
The system is pretty simple and easy to R&R except of course for the circlip. I'm sure if you need kits that "All Balls Racing" would list what you may need, or all the parts can still be procured from Kawasaki I would think. Good luck,
Dave

[kevinr]

Thanks for your help. I've gone ahead and ordered a rebuild kit for the master, and a found a pair of the thin elongated pliers. Hopefully that will take care of it. I'm away from home for work, and didn't want to have to await additional time to order after I got back. I'm feeling pretty confident that the fluid is leaking from the master cylinder back into the reservoir, but I'll confirm once I get the chance.

[Van Voyager]

Probably preaching to the converted...

Brake fluid is corrosive to paint so take great care when rebuilding the system not spill any fluid.

[vxiirider]

(Brake fluid is corrosive to paint so take great care when rebuilding the system not spill any fluid.)

It will also attack the plastic , so cover everything up and be careful.

[kevinr]

The rebuild fixed the issue. Also discovered the wheels were sticking.. cleaned and greased the calipers and it's running pretty good now. Thanks again.