afinepoint Posted November 17 Share Posted November 17 Installed new clutch on 2007 800a. Flushed clutch fluid. Changed oil using Honda recommended type. Motorcycle did well for ride around neighborhood which is about 2 miles. Took bike out today. Was not engaging after about half a mile. Worsening until there was no engaging at about two miles. Friction point was moving farther and farther on the lever. The correct clutch pack was installed using a manual. New pressure plate springs. All bolts torqued to spec. Clutch area inspected and nothing unusual found. Clutch lever is snappy. Pressure plate springs are pushing back. Thoughts? Quote Link to comment Share on other sites More sharing options...
Member Contributer Terry Posted November 18 Member Contributer Share Posted November 18 Those are the symptoms of a blockage in the master cylinder I think. The small relief port gets blocked, and that prevents pressure releasing from the line. As you work the clutch and/or the fluid heats, the line pressure increases and starts holding the plates apart. Quote Link to comment Share on other sites More sharing options...
afinepoint Posted November 18 Author Share Posted November 18 Like a check valve.. That makes sense. I was thinking the pressure plate is acting like it's being held away from the disks. Quote Link to comment Share on other sites More sharing options...
Member Contributer expvet Posted November 18 Member Contributer Share Posted November 18 The master/slave on the clutch can be tricky to bleed properly. When I rebuilt both on my 6th gen it seemed as if the typical master to slave bleed had gone well but I was getting poor disengagement with the plates. Finally resorted to a slave to master fluid push with a syringe and that dislodged whatever air pocket was trapped. Quote Link to comment Share on other sites More sharing options...
afinepoint Posted November 19 Author Share Posted November 19 No pressure being retained. Opened bleed port on slave and little came out. Nothing found in master cylinder bleed port but I did not have a fine wire to probe. I just poked with a small paper clip. Placed bike on center stand. In gear rear wheel locks with clutch lever released and turns with resistance with lever squeezed. Started next day. Outside temperature 54°. Clutch engaged initially. Checked again with engine warm about 170°. Clutch lightly engage then wouldn't. Clutch friction point way to far out on lever. Almost at point where lever sits. I know the clutch pack is correctly installed. Quote Link to comment Share on other sites More sharing options...
afinepoint Posted November 19 Author Share Posted November 19 On 11/18/2023 at 12:37 AM, expvet said: The master/slave on the clutch can be tricky to bleed properly. When I rebuilt both on my 6th gen it seemed as if the typical master to slave bleed had gone well but I was getting poor disengagement with the plates. Finally resorted to a slave to master fluid push with a syringe and that dislodged whatever air pocket was trapped. This would cause poor disengagement due to the air bubble. My issue is the opposite. Great disengagement no engaging. Quote Link to comment Share on other sites More sharing options...
afinepoint Posted November 21 Author Share Posted November 21 Will rebuild master cylinder. Only kits exist can not get new master cylinder. Bike too old. So I will not be replacing the orifice but plan to blow it out. Quote Link to comment Share on other sites More sharing options...
Member Contributer Terry Posted November 21 Member Contributer Share Posted November 21 Definitely should be no need to replace the master cylinder, and actually if the master piston is not leaking you probably don't need to replace any parts. Just a full disassembly and thorough clean and inspection. In the floor of the master cyinder is a small metal plate that sits into the main intake port, when you pick that out you will see the tiny relief port below. The metal plate's function is to stop a jet of brake fluid exiting the master when the cap is off during bleeding. Make sure this port is clearly ejecting fluid as the lever is pulled. Quote Link to comment Share on other sites More sharing options...
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