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Display Mesage #104292


HELP!! No clutch
Written by douglasvanb on 6/8/2011 at 05:02 pm

Mike,

I just rebuilt my slave and master clutch cylinders last night (the clutch lever
was getting spongy for me). It's a pretty easy procedure if you follow the
manual. Start looking at what you'll need to do here:
http://www.directcon.net/lcshepp/PC800SMPage9-2.html

It's actually a pretty simple operation to rebuild both the master and slave
clutch cylinders. The two most difficult parts were removing the master
cylinder without dripping any DOT 4 fluid on the plastics (hint: use folded up
beach towels that you don't care about) and removing the retaining clip from the
master cylinder assembly.

There is also a chance you might need to replace the hydraulic line between the
master and slave cylinders. I would suggest you find a local company that can
make you a new one out of braided stainless steel. A local hose and pipe
company is fabricating me one right now at a very reasonable (sub-$45) price.
You can also buy a Honda OEM rubber hose from somewhere like ServiceHonda.com.
The Honda OEM part number is 22900-MR5-000. You will also need four (4) of
90545-300-000 (the crush washers for the banjo bolts).

As for rebuild kits, I purchased K&L Supply kits. The two part numbers you'll
need are 32-1081 (master cylinder) and 32-0129 (slave cylinder). I bought the
master cylinder kit from CASportTouring.com and the slave cylinder kit from
E-Bay.

You will have to remove some plastic from the bike but there is a good
tupperwear removal guide in the manual starting on this page:
http://www.directcon.net/lcshepp/PC800SMPage2-2.html It isn't too bad once you
get the hang of removing and replacing all that plastic.

Try adding DOT 4 fluid to your clutch reservoir first to see if that helps.
Then try bleeding the line after that. The final thing to do is rebuild the
clutch slave/master cylinders and replace the hydraulic line.

Hope that helps!

Cheers,

Douglas

Message Thread for message #104292

divein_southfl
6/8/2011, 03:43 pm
HELP!! No clutch
Well I have put about 600 miles on my just purchased '90 PC so now, with only 10,100 total miles my cluth is gone. Was taking it out for a spin and when I squeezed the clutch control and dropped it from neutral to 1st it bucked and died. Trie

    mac.hancock57
    6/8/2011, 04:03 pm
    HELP!! No clutch
    Hi Mike, The PC does not have a cable, it has a hydraulic?operated clutch.? You will have to check the fluid in the clutch master cylinder.? It will probably need replacing and bleeding.? You may have developed a leak.? Hopefully someone else

      divein_southfl
      6/8/2011, 04:59 pm
      HELP!! No clutch
      Thanks Mac! I went and looked and sure enough there was almost no fluid in the resevoir. I refilled it and viola I have clutch again! So now i just have to figure out where the hydraulic leak is at. Hmmmm. Any suggetions anyone? --- In

        obijuanak
        6/8/2011, 05:06 pm
        HELP!! No clutch
        On Jun 8, 2011, at 08:59 , Mike wrote: > Thanks Mac! I went and looked and sure enough there was almost no fluid in the resevoir. I refilled it and viola I have clutch again! So now i just have to figure out where the hydraulic lea

    wbpc800
    6/8/2011, 04:09 pm
    HELP!! No clutch
    Mike, If you are lucky, you might get by with a simple fix. Right above the clutch lever is a reservoir that holds brake fluid to drive the clutch. I am pretty sure if you look through the sight glass on it, you will see that it is low or

      douglasvanb
      6/8/2011, 05:02 pm
      HELP!! No clutch
      Mike, I just rebuilt my slave and master clutch cylinders last night (the clutch lever was getting spongy for me). It's a pretty easy procedure if you follow the manual. Start looking at what you'll need to do here:

        divein_southfl
        6/8/2011, 05:14 pm
        HELP!! No clutch
        Thanks Douglas- all you guys here are awesome! --- In ipcrc@yahoogroups.com, "douglasvanb" <douglas.vanbo

          mrpacrat
          6/8/2011, 05:27 pm
          HELP!! No clutch
          If the reservoir has gunk in it or the fluid is discolored, you may get away with just cleaning the tiny holes in reservoir and pumping fluid through it until it runs clear. Then bleed it and test it. Mine were practically filled with a m

      divein_southfl
      6/8/2011, 05:04 pm
      HELP!! No clutch
      Thanks Wade- It worked and I'm back on the road. YEE-HAW! --- In ipcrc@yahoogroups.com, "Wade" <wbpc800@...>

        goldwingman40
        6/8/2011, 06:26 pm
        HELP!! No clutch
        Mike, Was there dirty deposits in the bottom of the resevoir? If there was did you cipe it out? If you didnt I would suck the fluid out of the resevoir and wipe it out and refill it. With either condition I would bleed clean fluid thru the

          divein_southfl
          6/8/2011, 11:24 pm
          HELP!! No clutch
          It looked like a little water was in the fluid when I topped it off. I spooned off the top layer before I closed it up. I know I should probably drain and refill and I plan on doing that on when I do the oil change in 2000 miles. Untill then

            obijuanak
            6/9/2011, 12:36 am
            HELP!! No clutch
            There IS water in the fluid. The only question is how much. Brake/clutch fluid is hygroscopic, meaning it readily absorbs water. Water would not float at the top of the fluid, it mixes well. You really should change the fluid NOW. While clutc

              mrpacrat
              6/9/2011, 01:27 am
              HELP!! No clutch
              Yes. Like Juan said. DO NOT wait to do it. It's important. > There IS water in the fluid. The only question is how much. Brake/clutch fluid is hygroscopic, meaning it readily absorbs water. Water would not float at the top of the fluid

              ymibhdu
              6/9/2011, 03:02 am
              HELP!! No clutch
              Flushing the clutch line is easy. I have done it while only removing the access panel. It is tight, but with some vinyl hose that fits tightly over the bleeder, it can be done without much trouble. --- In

                divein_southfl
                6/9/2011, 11:40 am
                HELP!! No clutch
                Really, I am standing right next to clueless here. What access panel? Anyone close to me (Ft Laud/Miami) that will trade some mechanical know how for a lobster dinner and beers? Or is there a step by step procedure (with pics, hopefully)that

                  gibinmich
                  6/9/2011, 12:38 pm
                  HELP!! No clutch
                  You really should get a Honda Service manual if you don't have one. The service panel is the small panel that is by the foot peg on both sides, they easily pop right off. The panel on the right side is over the oil fill plug and the one on th

            goldwingman40
            6/9/2011, 04:43 am
            HELP!! No clutch
            Mike, You DO NOT DRAIN the system or you will probably have trouble getting the air out of the system. If you don't know how to bleed the system find someone that knows how to help you. You can suck the fluid out of the resevoir and then soak