Question about 2001 Suzuki VS 800 Intruder

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Fluid reservoir for clutch handle seems to be leaking and there is almost no pressure when squeezed

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If it's leaking, that's why it doesn't work correctly. You need to ind where the leak is and fix it, then fill and bleed out the system.

Posted on May 22, 2011


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1 Answer

Help diagnosing a leak in my radiator system.

Hello Jeremiah, I agree you have a leak. The best way to find your leak is to use a cooling system pressure tester. Your leak could be as simple as a loose hose clamp or as complicated as a leaking water pump or a leaking head gasket .

Apr 27, 2015 | 1997 Plymouth Breeze

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Need help bleeding clutch on my 05 v-rod

As the clutch wears the fluid level in the reservoir will rise so the initial fluid level should not exceed the FILL LEVEL. And the motorcycle must be upright and the handlebars set to level the fluid in the clutch reservoir.

When filling an empty clutch fluid line, a VACUUM BRAKE BLEEDER with a fitting that mates to the secondary clutch actuator bleeder screw threads can be used to draw the fluid down the clutch line and the air out of the system.

Take off the clutch fluid reservoir cover and then initially loosen the banjo bolt just enough to allow air bubbles to escape. Be careful because clutch fluid under pressure can squirt a steady stream a long way.

Hold the reservoir cover in place and pump the clutch hand lever 5 times or so and then hold the clutch hand lever against the handlebar and with a shop towel under the fitting loosen the banjo bolt and watch fro air bubbles to be released and then retighten the banjo fitting and only after it is tight release the hand lever. Check and refill the reservoir with fluid to the FILL LEVEL line and repeat the previous step three or more times and until only a steady flow of clutch fluid without air bubbles escapes from the banjo fitting at all times keeping the clutch fluid level in the reservoir at the FILL LEVEL with motorcycle in an upright position.

THEN remove the secondary clutch actuator cover, cover the exhaust pipe(s) with towels and place a suitable pan under the right side case to catch excess clutch fluid THEN while holding the reservoir cover in place pump the clutch hand lever 5 or more times, then hold the clutch hand lever against the handlebar and loosen the secondary clutch actuator bleed screw and watch the bleed screw for air bubbles. When the hand lever touches the hand grip hold it there without releasing it until the bleed screw has been tightened again and then release the hand lever., refill the fluid reservoir to the FILL LINE and repeat the previous steps, always keeping the fluid reservoir full of fluid, until a steady stream of fluid with no air bubbles coming from the bleed screw. When there is no more air coming out leave the bleeder screw tight and fill the reservoir with fluid to the FILL LINE.AUTION

THEN test pressure by squeezing clutch hand lever repeatedly does not build pressure in the hand lever and the fluid level does not remain at the FILL LINE then there is a leak somewhere and it will have to be located and fixed. If there is no visible leak check the secondary clutch actuator boot for leakage.

When there is no evidence of leakage and the clutch lever works properly and the fluid in the reservoir is at the FILL LINE install the reservoir cap and insert and tighten the fasteners to 0.7-0.9 Nm (6-8 in-lbs); the reservoir banjo bolt to 23-31 Nm (17-23 ft-lbs); the bleed screw to 9-11 Nm (80-100 in-lbs); the secondary clutch actuator cover fasteners to 6-10 Nm (53-88 in-lbs) and then test ride the motorcycle.

If the clutch does not have correct pressure you may have a dragging clutch and/or hard shifting.

Jun 12, 2014 | 2004 Harley Davidson VRSCA V-Rod

1 Answer

1989 Honda gold wing 1500 // I am two days into my vacation and am loosing clutch lever resistance and there is fluid under the triple tree. Thane anyone don

Sounds to me like you have a leak in your hydraulic clutch system. Your clutch lever will start to feel odd as (1) fluid leaks out, reducing pressure; and (2) less pressure reaches critical areas because pressure over a certain level is squirting fluid out of the system.

Leaks like these are often caused by one of two things: (1) a hydraulic line that has sprung a leak; or (2) a leaking / cracked fluid reservoir on your clutch slave cylinder. I am discounting the possibility that the slave cylinder itself is going bad, as that wouldn't create fluid leaks external to the system.

To troubleshoot your system, top off the fluid reservoir and then squeeze the clutch lever repeatedly while looking closely to see where fluid may be leaking out. MAKE SURE YOU'RE WEARING GLASSES OR PROTECTIVE GOGGLES WHEN YOU DO THIS!! A pinhole leak in a hydraulic line can shoot out a thin but forceful jet of fluid, and that's really nasty stuff to get into your eyes (it's bad enough on your skin or on the painted surfaces of your bike). The leak won't dribble all the time, only when you're applying pressure, which is why you'll need to keep working the clutch lever while you're looking for leaks. The location of the leak will tell you a lot.

Though I can't see your bike, I'm leaning towards the idea that a hose or, more specifically, the metal end of the hose, is leaking fluid under pressure. If this is the case, you should be able to obtain a replacement hose/line from a Honda dealer and swap it out without too much of a bother. If you're in the middle of nowhere and can't get to a Honda dealer, it's also possible that a hose shop could fabricate a custom line for you if you're able to show them your old hose.

On the other hand, if you have a cracked reservoir, you most likely will have to replace the entire clutch actuating assembly (slave cylinder? clutch cylinder?). That part should be relatively exposed--it may be mounted to the handlebars out in plain view; you won't have to mess with the actual clutch inside the transmission. Because of the location where fuel is puddling, though, I think this is less likely than a hose / hose connection problem.

Good luck, and I hope this doesn't spoil your vacation!

Jul 25, 2011 | 1989 Honda GL 1500 Gold Wing

1 Answer

If you pump the clutch lever it will engage the clutch. when you pull in the lever without doing this it will not engage. How do i fix this problem?

Take cover off the clutch reservoir and check the fluid level. Fill it if necessary. Look for leaks between the clutch lever/reservoir, down the hose to the clutch slave cylinder. If no leaks visible, slowly squeeze clutch lever and release, watching for air or fluid pumping in the reservoir. Repeat until clutch has a solid pull. If the pull doesn't improve and stay good, you'll need to bleed the hose and slave cylinder. Locate the bleed valve at the clutch, squeeze the lever till it's a good solid pull, hold it in, and open the bleed valve. Watch for air bubbles. After doing this several times, you should get nothing but fluid. Refill the reservoir and close it. Good riding

Apr 18, 2011 | Suzuki VS 800 Intruder Motorcycles

1 Answer

Clutch reservior went dry. I could not shift. How do you fix this.

Any evidence of leaking frorm the clutch lever area or lines down to the clutch? Remove the cover on the clutch reservoir and fill. squeeze handle slowly to see if there is bubbles or fluid spray. Will most likely have to bleed the clutch. Bleed is on left side lower end of the clutch hose. Squeeze clutch lever several times and open the bleed. Close bleed and do again. When you get good solid flow of fluid, should have a good clutch. Look for leaks.

Apr 14, 2011 | Yamaha Royal Star Tour Deluxe Motorcycles

1 Answer

Bike has been sitting up for a year or two. I squeezed the front brake lever, which was really tight. It broke free but now there is no pressure at all. Not sure where to start.

Open your brake reservoir and check fluid level. Add fluid to proper level and slowly squeeze the lever, watching for bubbles or fluid flow in the reservoir. Check the brake calipers to ensure there is not a leak in that area. If no leaks, continue squeezing the brake until it is fully operational. May have to add fluid while doing this. Close reservoir.

Apr 13, 2011 | 2003 Suzuki GSX-R 600

1 Answer

Clutch wont work after sitting all winter. Shop says to take off reservoir top, straighten the bike so reservoir is straight, pump the clutch handle a few time and it should work. No luck so far

You probably need to bleed the sytem. Might as well start with fresh fluid.
Get a syringe without the needle, draw the old fluid from reservoir.....then refill with new fluid from a new container (brake fluid absorbs moisture from the air). Sit the diaphram back on the reservoir so that as you pump lever...fluid doesn't squirt over the side...brake fluid will destroy paint and fairing plastic if not cleaned immediately with warm sudsy water...always have a pail handy when handling brake fluid.
Find the bleeder bolt on your clutch slave.....on Yamaha its under a rubber flap on left side...Suzuki might be different). Attach a hose to bleeder and route to a waste container.Pump the lever a few times and while holding lever partially in...crack bleeder and squeeze lever to force the old fluid out....close bleeder, release lever....repeat the bleeding until new clear bubble free fluid is exiting. Monitor the reservoir level as you push out the old fluid and replenish as needed...if you run it will be fighting to rid the air out for some time.
You want the reservoir level to be about 60% full so it can expand with engine heat, before reinstalling the lid when done.

Mar 26, 2011 | Suzuki VS 1400 Intruder Motorcycles

1 Answer

1989 honda vt1100. the bike has no clutch feel. the lever is soft and wont disengage the clutch, master /slave works fine, i removed and held the slave from moving and the clutch lever was firm. the bike...

Hey End,
check out these components... one of them IS the problem.. make sure the system will pump fluid all the way to the bottom of the hose..THIS WILL REQUIRE TWO PEOPLE..and a can of fluid.. We are going to test the lever's ability to pressurize the hose...(This will help pinpoint the issue!!)..First.. remove the cover of the reservoir..(keep it level)...(DO NOT let the reservoir get low on fluid!!) one of you needs to remove the hose at the connection(#21 - master cyl. pic) will be leaking.. place your finger and thumb over the hose(prevent it from leaking).. have your helper fill the have your helper squeeze the lever.. see if you feel pressure on your finger and thumb..if not.. try putting the cover on the reservoir..and now try pumping the lever ...see if you get pressure at your finger and thumb.(it SHOULD blow fluid out!). IF THERE is NO pressure - no matter what you try..-- The problem is in the master cylinder.. (START from the BOTTOM pic first)..

The numbered pic's are the main culprits.. the problem is most likely in the master cylinder... -- then the clutch (#14 - #16) components...

PlEASE mark as helpful.... thanks


#8 or #9

CLUTCH For 1989 Honda VT1100C

#14 or #16


#4 is a M.C. rebuild kit.. #7 ..

Jul 25, 2017 | 1989 Honda VT 1100 C Shadow

1 Answer

Bleeding clutch

The best success I have bleeding my clutch is to do it in this order.
1- fill reservoir with dot 4
2-loosen bleed screw on slave cylinder and let gravity bleed
3-never let reservoir run out while gravity bleeding
4- when you see steady dripping fron bleeder screw, tighten screw.
5-top off reservoir with fluid and install top back on reservoir
6-loosen bleeder and squeeze clutch all the way in one time and hold it.
7-tighten bleeder before releasing clutch
8-repeat this step one more time
9-remove reservoir top and refill the cylnder
10-put top back on reservoir
11-pump clutch handle 5 times and hold in
12-open bleeder screw
13- repeat this step 3 times
14- you should have a good clutch
15-check fluid in reseervoir one more time to make sure it is still full

Jul 11, 2010 | 1997 kawasaki VN 1500 Vulcan Classic

1 Answer

My 1999 Aprilia rs125, No clutch.

Nope. Pressure plates use mechanical springs which don't fail with this symptom. It's your pressure cylinders for the clutch fluid. Either the main cylinder that is activated when you squeeze the lever or the slave cylinder that moves when fluid is displaced from the main cylinder. Check the fluid level in the small tank usually located on the handle bar and connected to the lever housing. No fluid = source of problem. Refill with the proper fluid. However, if the fluid has gotten very low, you may have gotten air into the fluid line and will need to "bleed" the system to restore good lever pressure and clutch function. Buy a repair manual...Chilton, Clymer, etc.. for your bike for details.

Sep 15, 2009 | 1999 Aprilia RS 125 Extrema

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