Author [NL] [FR] [ES] [DE] [SE] [IT] Topic: Clutch Problems  (Read 2993 times)

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  • Offline EXMX   us

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    Offline EXMX

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    • Bike: 2013 TTSE
    • City / Town: ST. JAMES, NY
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    Clutch Problems
    on: Aug 22, 2021, 07.24 pm
    Aug 22, 2021, 07.24 pm
    Two weeks ago I overheated the Trophy practicing slow speed maneuvers. As a result I temporarily lost my clutch, the bike stalled when I put it in gear. After letting it cool down for 30 minutes the TTse appeared to be operating normally. Two weeks later I took the TTse  out, after 3 miles the clutch started slipping then I lost all power to rear wheel. Any ideas on what kind of damage the high heat caused? Could the slave cylinder be damaged or the friction plates be worn out. I flushed the hydraulic fluid with new DOT 4 synthetic which did not correct the issue. There is approx. 27,000 miles on the TTse, and recently completed a 1,200 mile road trip with out any clutch issues.

  • Offline Coconut   gb

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    Offline Coconut

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    Re: Clutch Problems
    Reply #1 on: Aug 22, 2021, 09.37 pm
    Aug 22, 2021, 09.37 pm
    I would imagine from your description that the Clutch Slave Cylinder will be fine -
    Usually if the Slave Cylinder fails it will result in being unable to disengage the clutch,
    which is the opposite of losing drive.

    Removal, Inspection and Replacement of the Clutch is possible without removing the engine,
    and is described in Chapter 4 of the Service Manual - which I recommend is referred to,
    for the various references and use of the Service Tool required ( Clutch Restraint Tool T3880604 ).

    The Clutch Friction Plates may have become worn beyond their Service Limits,
    resulting in the loss of drive. ( Standard thickness = 3.80mm, Service Limit = 3.60mm ).

    If any of the Friction Plates are outside the Service Limit,
    then the complete set of Friction Plates should be replaced.

    There are 7 Inner Friction Plates, 2 Outer Friction Plates,
    plus 8 Steel Plates making up the Clutch Pack.

    The Steel Plates should also be checked for any bend / warp by placing them on a Surface Plate
    and measuring any gaps with Feeler Gauges.  Standard - Up to 0.15mm, Service Limit - 0.20mm. 

    Parts details here :

    Bike Bandit - Full Friction Pad Set is Item 5 - Approx US $175.60

    Also, due to the overheating, I would recommend changing the Engine Oil.

    Cheers  :821:

    Last Edit: Aug 22, 2021, 09.41 pm by Coconut

  • Offline Yaga1973   us

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    Offline Yaga1973

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    Re: Clutch Problems
    Reply #2 on: Aug 23, 2021, 01.42 pm
    Aug 23, 2021, 01.42 pm
    It will be interesting to see what you discover, EMEX.  Also, what was the cause of overheating?  Are your cooling fans working as they should?  How is your coolant level?  Keep us posted and good luck!
    Ride safe, ride often!

    One of the "New" Founding Members of the Twisted Trophies
    2009 Harley-Davidson Road King
    2017 TTSE - Blue (Sold)

  • Offline EXMX   us

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    Offline EXMX

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    Re: Clutch Problems
    Reply #3 on: Aug 23, 2021, 03.04 pm
    Aug 23, 2021, 03.04 pm
    I would like to thank you Coconut for your response, I have ordered the parts and will attempt the repair myself. I'm hoping the parts are readily available in the U.S.

  • Offline EXMX   us

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    Offline EXMX

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    Re: Clutch Problems
    Reply #4 on: Aug 23, 2021, 03.15 pm
    Aug 23, 2021, 03.15 pm
    Yaga1973, it was a hot sunny morning approximately 87 on an asphalt parking lot. I was trying to do 18 ft wide figure eights without any faults and lost track of the engine temperature, Holding the clutch in the friction zone and dragging the rear brake. It wasn't until I felt the clutch lever fading that I noticed the temperature. The coolant was at the proper level and the fans appear to be working properly when last checked with the dealer tool in April. I'm wondering if the deal tool checks the thermal switch for the fans. Letting the bike idle was not bringing the temperature down so I just shut it off and waited 30 minutes. I'll let you know when I find when I finish the repair.

  • Offline Coconut   gb

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    Offline Coconut

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    Re: Clutch Problems
    Reply #5 on: Aug 23, 2021, 06.18 pm
    Aug 23, 2021, 06.18 pm
    I think I'd have stripped the Clutch down and examined it first before ordering the new parts !

    Do you have access to the official Service Manual, and the required Service Tool ?

    There is some important information in the Manual about the assembly order
    of the Clutch Plates, and the various tightening Torques etc, etc.  ?

    Cheers  :821:


  • Offline janfmiller   us

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    Offline janfmiller

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    Re: Clutch Problems
    Reply #6 on: Aug 23, 2021, 07.27 pm
    Aug 23, 2021, 07.27 pm
    I'd check the fans and circuitry for sure, I ran my TTSE in NV at 120 in slow traffic, and never got more than 1 bar above normal...

    Be interesting to see what you find, an oil-bath clutch should be able to take a lot of abuse before wearing out... IMHExperience...
    1977 Suzuki TS-185
    1974 Kawasaki Z-1 903
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  • Offline Yaga1973   us

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    Offline Yaga1973

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    Re: Clutch Problems
    Reply #7 on: Aug 23, 2021, 07.38 pm
    Aug 23, 2021, 07.38 pm
    I'm with you on this one, janfmiller.  There has to be something else going on to cause it to overheat like that.  I purposefully purchased a liquid cooled motorcycle so I wouldn't have to worry about overheating and excessive heat soak.
    Ride safe, ride often!

    One of the "New" Founding Members of the Twisted Trophies
    2009 Harley-Davidson Road King
    2017 TTSE - Blue (Sold)

     



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