99,1500 Kaw Classic Clutch troubleshooting?

2644 Views 8 Replies 4 Participants Last post by bikeaholic, Mar 31, 2004

Big E

Discussion Starter · Mar 22, 2004

I'm pulling my hair out (well if I had any)...My Vulcan (4900 mi.) runs sweet for about an hour and then I start to lose the clutch in city riding(moderate stop and go driving). One minute It's fine and the next stop I'm pulling a soft lever and killing the engine because I can't shift down, up or inbetween. Reservoir is full and I have no leaks that I can find. I hate to wait over a week in line at the service shop. I'm not mechanically challenged but have very little bike experience. I have a service manual but any direction I can get would be appreciated. I just started riding again after 25 years and bikes have evolved a little since the last time I wrenched on one. Thanks in advance for any help.

Save

1 - 9 of 9 Posts

hiway_dominator

· #2 · Mar 23, 2004

1500 clutch trouble

If you aren't losing any fluid that you can tell, the lines may need to be bled. I just replaced all my hoses and cables w/ stainless steel ones and realized what a bitch it can be to get new lines completely airfree.
If it were me, I would check all fittings and bleed them per the svc man.
good luck.

Save

hiway_dominator

· #3 · Mar 23, 2004

Save

hiway_dominator

· #4 · Mar 23, 2004

Save

Big E

Discussion Starter · #5 · Mar 23, 2004

Thanks hiway......I'll give it a try

Save

ZX-2R

· #6 · Mar 25, 2004

CLUTCH

AS long as it is adjusted right, and yo can't find any loose line, it must be air in the line. It probably wouldn't hurt to just replace the brake fluid as you are going to bleed them anyway. Stay on top and give us the feedback on the FORUM!!!

Save

Big E

Discussion Starter · #7 · Mar 29, 2004

Thanks for the advice, I bled the line. The clutch works fine for about an hour, maybe 1-1/2 stop and go city driving. Then it seems to get stuck in gear and wont shift. Again the clutch feels very spongey. Once the bike sits for a day it all seems normal again. The bike went into the dealer last week and they say they can't find a thing wrong with it. I made them keep it and convinced them to test ride it for a while. I was told if they can't find anything they will call Kawaski today. Talking with the mechanic, there has been problems with other models in the past (not vulcans) where the position of the reservoir and the angle on the handle bars has allowed air to get into the lines and cause a similiar problem. That was a few years ago. Hopefully they will find something or get some suggestions from Kawasaki.

See less See more

Save

Big E

Discussion Starter · #8 · Mar 31, 2004

Well the dealer couldn't find anything and Kawasaki has no known history of this type of problem. Recommended solution is to keep driving it until the problem becomes more prominent. Nice customer support to a potential accident waiting to happen. I am not a happy camper. 3 hours on the mechanics lift, 20 miles of test driving and the dealer says no charge, no paperwork....great way to avoid any liabilty! If anyone has any other suggestions I am all ears....in the mean time I guess I will just tear the whole thing apart and rebuild the clutch and hydraulics from the ground up. Maybe I'll have time to ride the **** thing before summer ends.

Save

bikeaholic

· #9 · Mar 31, 2004

re

is this bike under warranty? and is the factory oil still in the tranny?

Save

1 - 9 of 9 Posts

This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.

Top Contributors this Month