Kawasaki Vulcan 1500 Clutch Problems: Symptoms, Reasons, Solutions

The Kawasaki Vulcan 1500 was launched back in 1987 as a cruiser motorcycle by Kawasaki and stayed in production until 2008. Referred to as the "Kawasaki's King Cruiser" in the 1987's May issue of Popular Mechanics, the Indian-inspired two-wheel cruiser looked every part with its enormous engine and stylish exterior. Surprisingly to most bike enthusiasts at the time, the Kawasaki Vulcan 1500 defeated the infamous Harley-Davidson Evolution Motorcycles in both power and style.   

The Kawasaki Vulcan 1500 is a top-of-the-line motorcycle when it comes to cruisers, with massive power, exemplary bodywork, and spectacular road performance. However, like any other machines on the road, the all-powerful Kawasaki Vulcan 1500 cruiser also has some problems of its own. If you have been riding a Vulcan 1500 for long enough, then you are probably no stranger to your cruiser having one too many clutch issues. 

If you have been part of the Vulcan 1500 clutch failure club, then you already know how frustrating and even dangerous it can be if your motorcycle's clutch is not working properly. With the Vulcan 1500's hydraulic clutch system, it can go from operating flawlessly to not having any resistance when squeezing the lever at all and even having to force it to 1st gear.

So if you are an owner of a Kawasaki Vulcan 1500, below are some common symptoms, reasons, and solutions to help you deal with any upcoming clutch issues with your cruiser.    

Kawasaki Vulcan 1500 Clutch Problem Symptoms

The Kawasaki Vulcan 1500 is equipped with a 4 or 5-speed manual with a wet multi-disc clutch assembly. Since the clutch is lubricated with oil, the oil used to lubricate the 1500 wet clutch plays a huge role in the usability and effectiveness of the clutch system. Clutch problems can not only be frustrating but also affect other major parts/components of your Kawasaki Vulcan 1500 if ignored or left unattended.   

To transfer energy and employ the clutch, the mechanical clutch has to use a cable and levers. The hydraulic clutch on the other hand uses a totally incompressible fluid and the clutch is self-adjusting and only needs fluid changes. Below are some common tell-tale symptoms for you to detect any early signs of clutch issues with your 1500 to avoid more severe damages in the future.     

• Difficulties Changing Gears

Having a difficult time changing gears is one of the most common symptoms of a failing clutch. Being able to smoothly shift gears according to the road conditions makes the riding experience more pleasant and safe on the road. If you feel the clutch is too stiff or having a hard time changing gears to attain the ideal speed, it may be time to change the clutch.    

• Clutch Slippage/Poor Acceleration

The clutch slipping and resulting in poor acceleration is another common symptom of a faulty/failing clutch. The clutch will begin to slip when the pressure plate fails to keep the friction plates in position against the flywheel as needed. Even if the flywheel and the pressure plate are locked, they can continue to rotate at different speeds.

This will cause the engine's power to not get properly transferred to the rear wheel and you will feel your clutch slipping. It is common to experience the effects when you try to push the throttle for more speed. Although the engine will rev aggressively, your Vulcan 1500 will fail to correspond to the throttle input and not accelerate as per your expectation.  

• Unusual Noises

If any unusual noises occur or even if you feel that something underneath is grinding, it is safe to assume that your 1500 may be experiencing some clutch issues. The noise may start off faintly and gradually grow louder while accelerating or changing gears. If you notice such noises or feel any excessive vibration while driving off or releasing the clutch after shifting, you should examine the clutch for wear-n-tear or other damages.    

• Not Getting into Certain Gear

The gear shifts of your Kawasaki Vulcan 1500 are directly linked to the clutch. So it is only natural that if there are any issues with the clutch, it will result in difficult or dangerously unpredictable gear shifts. While you may find some gears very easy to shift into, there may be others where it may seem almost impossible to engage.         

Reasons/Causes for Kawasaki Vulcan 1500 Clutch Problems

The Kawasaki Vulcan 1500 comes with a hydraulic clutch with the clutch reservoir being on the left side of its handlebar. With temperature changes and daily use, the hydraulic clutch system ends up becoming one of the main reasons for slipping clutches, damaged transmissions, and needing urgent roadside assistance. Most mechanics recommend first checking the oil if there seem to be any issues with your Vulcan 1500 clutch system.

Also, the Kawasaki Vulcan 1500 tends to have a weak clutch spring and can wear-n-tear faster than usual. Kawasaki does not use multiple coil springs and a bearing type of pressure plate. Instead, they use a single spring that is beveled and the collar is in the middle so it rides on nothing else but the spring itself.  

So if you are the type of rider that likes to sit at a stop light with the clutch lever pulled in waiting for the signal to change, you are putting unnecessary pressure on the clutch springs. You should not hold the clutch lever for a lengthy period. When you constantly hold on to the clutch lever pulled in on your 1500 for an extended time, you are actually speeding up the natural wear-and-tear process.  

You have to try to avoid holding in the clutch lever for too long to avoid premature clutch failures. If you are a Vulcan 1500 user, it will help to change up your riding style and put your motorcycle in neutral and release the clutch at a stop light. Furthermore, if your springs are indeed worn out and need replacement, it is also better to change the oil filter since it may be filled with metal dust from when the collar ate into the clutch spring.       

With a hydraulic clutch system, there are also some underlying faults to look for such as oil contaminations and various leaks. Hydraulic fluid getting contaminated or even using the wrong type of fluid are common reasons leading to issues with the clutch master and slave cylinders. The cylinders can easily seize due to the rubber seals within the cylinder swelling up from contamination.

The smallest drop of engine oil, gearbox oil, washer fluid, or even antifreeze can result in contamination. Using the same funnel with traces of different types of fluid can also introduce contamination into your Vulcan 1500's hydraulic system. The best solution is to completely bleed or flush the old hydraulic fluid out of the circuit to replace it with new and fresh fluid.  

Although bleeding will eliminate most contamination issues with the hydraulic clutch system, replacing the fluid will not help if there is a leaking line, a leaking master/slave cylinder, or even a clutch release piston.

A leak or broken master/slave cylinder will not be able to pressurize the hydraulic fluid and eventually will get to a point where the clutch will not be able to disengage at all. So before you end up bleeding a hydraulic system that is leaking, it would be better to take a look around to see if any leaks are causing a loss of fluid.       

Solutions To Help with Kawasaki Vulcan 1500 Clutch Issues

With a hydraulic clutch system, you may need to either dismantle and clean the master or slave cylinder if the clutch feels too stiff to squeeze. Once you disconnect the slave cylinder and operate the clutch lever, you can easily determine which one needs to be serviced. The issue may be due to the slave or master being faulty as well.         

As mentioned earlier, with a wet multi-disc clutch assembly, the oil plays a crucial role, and changing the fluid in the system is never a bad idea. Since hydraulic fluid absorbs moisture over time and usage, the piston will seize due to the contamination from that moisture. Bleeding the system and replacing it with new fluid as well as faulty seals and parts will resolve most of the common issues with your Kawasaki Vulcan 1500 clutch system.  

Conclusion

Since launched in 1987, the Kawasaki Vulcan has become an icon that has come a long way with its massive success. Living up to the moniker of "King of Custom Cruiser Bikes", the Kawasaki Vulcan 1500 series has released 11 models along with 21 trims not only in Japan but also in Europe and North America. Although some recurring clutch issues seem to be pretty common amongst the Vulcan 1500 users, they can be avoided/prolonged with a little bit of proper maintenance and adaptive riding habits.  

Staying on top of changing the fluids of the hydraulic regularly can very easily extend the health of your Vulcan 1500's clutch system. In case of any contamination issues, simply bleeding or flushing out the circuit and putting in the new fluid will usually solve the problem. Just make sure that your clutch system does not have any leaks where bleeding will only be a waste of time if the fluid continues to leak out.