Almost got stranded - clutch problem

[ORBrit]

So I had to ride up to Portland for a client emergency - gorgeous day - sunshine and about 55 degrees.
The ride was about 110 miles from my house to the office. I got up there and fixed the problem and set off home about 5:45pm

I'm on the freeway for 100 miles and cruising along happily.

I exit the freeway and the first time I slow down and downshift, I notice my clutch is way spongy - very little resistance until about 2/3 of the way through the range of motion.
The shifter is way notchy too.
I notice as I come to a stop that I have to almost have the clutch lever pulled all the way in to disengage the clutch.

The next 15 minutes of in town riding, gets worse. The clutch is not fully disengaging when the lever is pulled in completely.
About 5 blocks from my house, I cannot shift at all - up or down.
I come to a stop sign and the bike stalls. I get it into Neutral, and with the clutch lever in, I kick it into first and the bike jumps forward, so I just go with it.
I try to shift -with no success. I try the engine kill switch - the bike keeps running (basically like a bump start). The clutch lever is completely useless.
I push the bike the last 2 blocks home.

I could have been stranded in Portland, 100 miles from home.

What do you think the problem is? Clutch fluid?

Bike is a 2007 Suzuki Boulevard S50.

Help!

[omegajim]

I believe this is a cable clutch (vs hydraulic)

let's go from there. You described this got progressively worse in a very short distance.

My first thought would be a stretched clutch cable.

That said, before I even replace the clutch cable, the old bikes (aka, I don't know the suzuki system) there should be an adjuster (the cable will have threads on it where it goes into the clutch housing on the side of the engine) and you can adjust there.

Your bike is new enough that the cable should be the problem, or an adjustment to the cable will be the problem.

It is unlikely that it is anything more serious than a bad clutch cable.

but, that said, before you replace it, make sure you have tried to adjust the clutch cable tension before proceeding further.

[B-Rex]

Originally Posted by ORBrit

What do you think the problem is? Clutch fluid?

Bike is a 2007 Suzuki Boulevard S50.

Help!

I'm no bike mechanic and its been years since I did my own work (I'm putting my dealer's kids through college). That being said, in my experience, a dramatic clutch failure was almost always a linkage/control failure.

If your clutch is cabled, it may have come loose from its attachment inside the clutch cover.

If it's hydraulic, I'd check fluid/seal status. While you may not see it leak, your fluid level ought to be pretty low if it is.

Like I said though, I'm no mechanic but I'd check those things first before I dragged it to the dealer. Sorry, I don't know more and can't be more useful or specific.

However, I'm hoping it's something cheap and easy to fix in the clutch linkage and not a transmission fork or dog problem (though it doesn't sound like it since you can't disengage the clutch at all now).

My guess is there are plenty of competent "wrenches" here who will diagnose it two seconds after they read your description. Best of luck!

B-Rex

[ORBrit]

Originally Posted by omegajim

I believe this is a cable clutch (vs hydraulic)

let's go from there. You described this got progressively worse in a very short distance.

My first thought would be a stretched clutch cable.

That said, before I even replace the clutch cable, the old bikes (aka, I don't know the suzuki system) there should be an adjuster (the cable will have threads on it where it goes into the clutch housing on the side of the engine) and you can adjust there.

Your bike is new enough that the cable should be the problem, or an adjustment to the cable will be the problem.

It is unlikely that it is anything more serious than a bad clutch cable.

but, that said, before you replace it, make sure you have tried to adjust the clutch cable tension before proceeding further.

It's definitley hydraulic. I looked this morning when it was light and the reservoir was low. I'll start with a complete clutch fluid bleed, using Dr. Bob's write up

[Clint]

You'll have to investigate the source of the leak. Such a new bike shouldn't be low already, even without regular checks.

[ORBrit]

that's the thing that concerns me - I have a prepaid maintenance agreement and it's been in for 2 full services, and oil changes in between - most recently about 2 weeks ago!

[omegajim]

they may have missed it.

that said, the fluid being low on a newer bike is a problem.

especially if the fluid is leaking onto the plates.

[MikeHump]

Is there even clutch fluid? I'm not too familiar with bikes yet, but I thought most have a wet clutch design, which uses engine oil as lubrication.

[themeatmanlandry]

Originally Posted by MikeHump

Is there even clutch fluid? I'm not too familiar with bikes yet, but I thought most have a wet clutch design, which uses engine oil as lubrication.

The fluid is in the clutch line itself and acts to engage/disengage the clutch plates. Sort of like the cable, except fluid pressure does the trick. Yes, the clutch plates are lubricated by the engine oil, but we are talking hydraulics as opposed to lubrication.

[MikeHump]

Ahhhh, it's all so clear now. Thank you

[ORBrit]

I bled the clutch fluid and topped up the master cylinder - it was empty!!
I still haven't located the source of the leak and have the proper feel back in the clutch lever again.
I'll ride tomorrow to make sure it is funtioning as it should. I tested the friction zone today after working on it but didn't have time to ride.

[JmalB]

Sounds like a warranty check to me. Oh wait motorcycles aren't real vehicles and don't come with useful warranties... <grumble>shouldhavepostedinrants<grumble>

[themeatmanlandry]

Originally Posted by ORBrit

I bled the clutch fluid and topped up the master cylinder - it was empty!!

THAT leak should be easy to find I would assume. Have you seen spots where you park?

[ORBrit]

nothing where I park.
I do have an extended warranty that came with the prepaid maintenace program. I'll take it in this week.

[themeatmanlandry]

Originally Posted by ORBrit

nothing where I park.
I do have an extended warranty that came with the prepaid maintenace program. I'll take it in this week.

Never having owned a bike with a hydraulic clutch, I feel sort of dumb saying this, but it sounds like the leak is going on inside the casings and potentially contaminating the oil. I don't know if that's possible, but that %%%%'s going somewhere. A whole reservoir full of fluid should have left a mark . . . wither on the ground or on the bike.

Where do you park it? Is it safe and secure?

Keep us posted, as this is definitely turning into an interesting one.

[B-Rex]

Originally Posted by themeatmanlandry

Never having owned a bike with a hydraulic clutch, I feel sort of dumb saying this, but it sounds like the leak is going on inside the casings and potentially contaminating the oil. I don't know if that's possible, but that %%%%'s going somewhere.

Yep, that's dead-on correct and ultimately the real problem. If the slave/actuator is inside the case and it's the source of the leak, then contamination is highly probable. As I noted earlier, you may not see the leak but that doesn't mean it's not leaking.

B-Rex

[wildwolf]

Bleeder bolt could have vibrated just a bit lose...enough to lose the small amount in the reservoir on a 100+ freeway ride easily e/o you really noticing. Especially on this bike with the sight glass on the opposite side of the rider. If I had to guess where the fluid went, that'd be mine.

I must also say, that's a fine looking blue bike in Dr. Bob's write up.

[ORBrit]

I'm going to check the sight window frequently as I test ride it to see if hte level starts to drop.

to be honest I'd never checked it before this happened!

I park the bike in the 3rd bay of our garage so I would see liquid on the concrete floor if it was an external leak.

When I bled the fluid, the bleeder bolt was on real tight - and the "bango bolt" was really really tight. I had to loosen that because even after bleeding it the clutch lever was soft. I squeezed quite a bit of air out of it!

So far it still feels normal since the bleeding but I've yet to test ride it.