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hey guys
its the gustafsons again
were gearing up to come down for wauzeka
but i have a problem. .
hoping one of you could help

i have a clutch problem
i dunno' it seams like the master cylander is working and applying pressure, however the slave
moves a little, but not enought to engage the clutch,
what can i do??
im lost, i cleaned out the whole system and put new fluid in, butthat didnt help
can i get a rebuild kit or something for it?
or am i looking at a whole new clutch?

Are you sure that the problem isn't that there is just some air stuck in the system?

I changed front and rear brake fluid and clutch fluid early this spring and had good results with pressure filling the systems through the bleed screws.  You should be able to get a large syringe and a piece of clear tubing from about any farm supply store.  Fill the syringe with brake fluid and push the fluid in the bleed screw until the reservoir is at the proper level and tighten the bleed screw.  This worked pretty well for the clutch and front brake.  The rear required a bit more effort - disassembly and careful positioning of components.

If the clutch (slave) cylinder was leaking, your reservoir level should be dropping.

Hope this helps.
Jim

What is the problem you are having with the bike? The reason I’m asking this is because you stated that your were having trouble with the clutch “engaging“. When you pull in the lever on the clutch you are actually trying to disengage it. If the problem is that the clutch is not engaging then I would think it is more a problem with the clutch itself. The clutch plates may be stuck open, or the slave may be stuck and holding the clutch open.
 If the clutch is staying engaged and not disengaging when you pull the clutch lever (more likely to me) then it could also be a number of things. The clutch plates could be stuck together.  You could try letting the bike warm up good and try riding it working the clutch to try and get them to separate. Most likely if you haven’t ridden it for a while.
If the master cylinder reservoir fluid level goes down without seeing a visible leak then you could have a leak at the slave. There are 2 o-rings that could be leaking.
You could have dirt or some other contaminate in the master cylinder and causing the  plunger to lose its seal and keeping it from building pressure.
The worst case would be that the clutch fingers are bent and not opening the clutch or the clutch plates are damaged .
There are rebuild kits available for rebuilding your master cylinder and slave. They also have kits to convert older bikes that use brake fluid for the clutch to a system that uses hydraulic mineral oil system.
I know its a lot but I hope this helps. 8)

hey you guys are awesome for your help
i understand i must have said the incorrect thing about engaging, disengaging
when i pull the level in, the pressure is there, however i cannot roll the bike. . .
i took EVERYTHING apart, level, master, slave cylander,
new oil, cleaned all those rings up, yes it was very gritty
i had someone put a little air pressure to push out the slave so i could clean it,
put it back together, put the new oil in, pumped it, bled it, pumped it, bled it. . etc. . .
got most of the air out, got oil down to the slave, and squirts out the bleed "valve"
pushes slave cylander out a little, however when i put it on the bike, doesnt seem to "push" into the bike far enough to DISengage the clutch
all o-rings seem to be fine, cleaned them up, oiled them up, threw them back in
i am definatley going to try "Hackman"s advice and let it arm up for a while, it DID sit all winter. . .

Sounds like you fellas are on the right track.  Almost surely just a problem with clutch discs stuck together.  If it hasn't broken loose after warming up, I usually hold the clutch in and ease into the throttle and rear brake at the same time until the clutch breaks free.  Be aware: When it does break loose, the bike stops REALLY fast.

Jim

hackman as right
i let it warm up, a lot
kept pumping the lever. . .
slowing to a crawl with the clutch in, and finally it gave way and idled. .
thanks a lot for your help
ill see you guys in wauzeka. . .