Hydraulic clutch becomes stiff when warm??

turbotwerp · May 22, 2006

I have an 01 M750 with a hydraulic clutch. The clutch operates perfectly the first few miles I drive the bike. It is nice and smooth and travels all the way to the grip. After about 10 miles however, when the bike fully heats up, the clutch becomes really stiff, and offers alot of resistance. It only travels about half way in (still enough to disengage the transmission) and takes about twice as much force.

I recently had to take the fork off and had the clutch disconnected. I filled it up according to the standard procedure.. used new fluid, burped the bubbles out of it, etc. Anyone have any ideas what the heck is going on? Bad fluid? Overfilled? Do I just need to flush it out again or is this something else?

ducpainter · May 22, 2006

Not certain, but it sounds like the pushrod or something is binding. I have never heard of hydraulics getting stiffer if there was air in the system.

turbotwerp · May 22, 2006

Yeah I was afraid of that. I can't imagine anything is wrong with the line... fresh fluid and all.. no kinks.

I have done alot of work on this bike but I've never had to play with the clutch. Is it difficult? How would you go about checking / fixing a binding pushrod?

ducpainter · May 22, 2006

You can check the pushrod to see if there are any strange marks or gouges by removing the slave, and pulling the pushrod out. Two questions. Has the bike had any clutch work previously, and did the problem start after you messed with the master?

turbotwerp · May 22, 2006

Unfortunately I don't know if the clutch has been tinkered with before. I bought the bike used a couple months ago. The bike is practically new but I'm guessing had some minor front end damage and the headstock was tweaked. I had to replace the frame so I pulled everything apart including the clutch line. I had only test ridden the bike at that point.

When I put it back together the clutch worked fine for about 200 miles. Now all of sudden it starts binding up. Everything else about it is fine... it doesn't slip, engages smoothly and feels like it has plenty of life left in it.

brad black · May 22, 2006

sounds like it needs the recall, if it is an '01. http://www.moto-one.com.au/performance/clutch_slave_cyl.html

ducpainter · May 22, 2006

I would listen to Brad. [thumbsup]

turbotwerp · May 22, 2006

holy crap. thanks for the article, i think this is exactly what is happening. it goes in halfway and then jams. what a bizarre problem.

looks like i'm out $200 bucks for a new slave cylinder though.. i doubt the ducati shop will grant the recall on a totally rebuilt bike with no warranty. are they obligated to or am i screwed?

test-reg · May 22, 2006

turbotwerp said:
holy crap. thanks for the article, i think this is exactly what is happening. it goes in halfway and then jams. what a bizarre problem.

looks like i'm out $200 bucks for a new slave cylinder though.. i doubt the ducati shop will grant the recall on a totally rebuilt bike with no warranty. are they obligated to or am i screwed?

This is a NHTSA safety recall, not a warranty issue. Remove the slave and see if there is a weep hole . If there is no weep hole DNA owes you a new one. Unfortunately I have no picture for you.

SlickRick · Jul 8, 2006

Umm. what is a weep hole? :-\

(I have an '01 M600)

Desmo Elmer · Jul 8, 2006

Umm. what is a weep hole?

Read Brad's link. Vent hole in the pic.

Hydraulic clutch becomes stiff when warm??

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