Clutch Failure

[wvvarider]

I recently purchased a 1999 Valkyrie from a guy that did a lot of  work to restore this bike after sitting idle for some time.   When I bought this Valkyrie it ran well and only had 16200 miles.  The clutch lever only came half way to the handlebar but did shift well for the 200 miles I was able to ride it.  Shortly after I changed the clutch fluid, the clutch would not disengage. Shift into neutral and bike would pull while clutch lever in, also unable to shift out of first while engine running.  At this point I rebuilt the clutch master cylinder and installed new lever pins—no change.  Then I rebuilt the slave cylinder—no change.  I must have air in the line, right? I’ve bled the line many times and even repositioned the awkwardly mounted master cylinder so no air would be trapped in the banjo bolt—no change.

Any suggestions before I tear into the clutch itself?

Maybe the clutch plate rivets may have given up after waking up this sleepy beast from its long slumber?  Although it’s now an antique, I would never guess clutch failure at 16K miles.  

[Chrisj CMA]

Clutch handle stopping half way=bad clutch rivets almost 100%

[PSUbag]

Check/replace the brass bushing at the end of the lever first. Worth a shot.

[wvvarider]

handle bushings were replaced when master cylinder rebuilt. Clutch lever only goes to handlebar when low fluid or lever strapped down.  I'll tear into clutch within a month and post the findings. I bet it's bad rivets too.  all the easy stuff has been rebuilt.

[F6Dave]

Clutch damper plate replacement isn't as bad as it looks. I did mine without any special tools. I re-posted my photos and suggestions for the tricky parts not too long ago. I can post them again if needed.

[Dirty Dave]

I agree. Sounds like the damper plate is falling apart. The little semi-circular metal tabs between the
damper plate halves get free and stack up on one another when the rivets fail. This jams the clutch.

The plus side is after the repair, it's like butter. (My wife makes fun of me whenever I say that)
I just can't get over how smooth it is now. Musta been slowly on the way out . Gave up the ghost
after one particular energetic  outing.

[wvvarider]

Chris J was exactly right. . failed rivets.  My 1999 Valkyrie only has 16000 miles yet once I opened the clutch found rivets laying the cover and a few plates seized.