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Clutch Wont Disengage

Started by Adamdrives, April 02, 2024, 11:00:50 PM

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Adamdrives

Hi All,

After getting my 90 FJ running under full power after a long hibernation and years of neglect, I noticed that the clutch slipped in 4th gear and above. After searching the forums, I decided to try the double clutch spring trick. It worked! No more slipping. Unfortunately, this also exacerbated a different, related issue.

The bike has always crept a little at a stop, in 1st gear with the clutch lever fully in. Enough that if I stand up off the seat, I can feel the bike creeping forward. After adding another clutch spring, the issue was much worse. Now the bike wants to pull unless I pull the brake, and then I can feel the engine bogging. It was also tricky to get into neutral before, but now, its impossible with the bike running.

Thinking that my issue might be a leaking slave cylinder, I ordered a rebuild kit. Opening the slave showed a lot of corrosion, gunk and hardened seals, so I thought I found the source of my issues. Not the case. After rebuild, and extensive bleeding, the symptoms were the same.

Unfortunately I have not been able to find a suitable kit for the clutch master. The Yamaha part number 2KW-W0099-00-00 shows a kit with a screw type piston, while mine is smooth, similar to the brake master piston.



I'm hoping this is the source of my issue, even though the seals are soft and the bore has only light scoring. Anyone know where to find a rebuild kit that matches? Even my Clymer shows a diagram of the piston with the same design as what I removed from the bike (1st pic), unlike all the kits I see on eBay (second pic) that reference to the Yamaha part number.

Or, could there be another source of my issue? I noted that with the clutch cover off, when I squeeze the lever in, only about half the clutch plate lifts, leaving one side still making contact.
1990 FJ1200 6.7k mi Restoration

Old Rider

Unless you have a FJ1100 clutchmaster you have the wrong mastercylinder piston. The FJ1200 uses the screw shaped piston.

Adamdrives

Do you think somebody installed an 1100 master in? The piston that came in the rebuild kit had a larger diameter and would not fit in my master, so that must be the case.

Well, I guess I'll just order a rebuild kit for an 1100 for now. Thanks!

Edit: Any idea what year 1100? Part catalog shows 36Y-W0099-00-00. When I plug that into eBay, I get rebuild kits with the same screw type piston.
1990 FJ1200 6.7k mi Restoration

RPM - Robert

Yamaha FJ1100 Clutch M/C Rebuild Kit

You might want to try the world's leading supplier of FJ specific parts.

fj1289

Awwww, come on Robert - not everyone likes getting the right parts at a good price quickly - some people must get a rush gambling on eBay, etc!

Pat Conlon

We need to get that RPM banner back at the top of the page...

....and the "donate" button back on the bottom. 
1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3

Sparky84

Quote from: RPM - Robert on April 04, 2024, 10:21:32 AMYamaha FJ1100 Clutch M/C Rebuild Kit

You might want to try the world's leading supplier of FJ specific parts.
Quick questions Robert,
what's the little bottle of oil for with the clutch rebuild  kit?
And why don't you get it with the brake rebuild kit?

This has always puzzled me, I think I've still got a few of those little bottles
1984 FJ1100
1979 Kawasaki Z1300
1972 Honda CB750/4 K2

RPM - Robert

I am pretty sure it is assembly lube/ maybe even brake fluid. I have never opened one up, Yamaha only send them with the 1100 kits and no others. I use the brake fluid we will be using in the system to assemble so I have never even opened those bottles.

Sparky84

Quote from: RPM - Robert on April 08, 2024, 11:18:41 AMI am pretty sure it is assembly lube/ maybe even brake fluid. I have never opened one up, Yamaha only send them with the 1100 kits and no others. I use the brake fluid we will be using in the system to assemble so I have never even opened those bottles.
Thanks Robert, I've never opened one either.
1984 FJ1100
1979 Kawasaki Z1300
1972 Honda CB750/4 K2

Adamdrives

Well, the 1100 kit doesn't fit either. I think I have some type of universal aftermarket master installed. The previous owner definitely was not honest about the bikes history and I didn't know any better. Will link a pic of my master later.

I'm just going to buy a refurbed 1200 assembly. Enough of this.

1990 FJ1200 6.7k mi Restoration

RPM - Robert

With no pictures of the actual master cylinder hard to say. You have one picture of the bike without the fairing on it. It appears the clutch master is square but the picture isn't clear enough to tell. If it is, a common mod is the FJR clutch master. This gives you a little softer pull and an adjustable lever.

Pat Conlon

Yes, the FJR clutch master is what you want....
1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3