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All,
I would really appreciate your input into potential reasons that my friction zone changes while I'm riding. When I start up my 1998 ST2, I get engagement when the clutch lever is about half-way out. But while I'm riding, it will sometimes change to getting engagement from about 3/4 to fully extended. At any given time, I don't know where the friction zone is. I've replaced the clutch master cylinder and clutch fluid line, but the issue still occurs. I can't find any loss of fluid from the clutch line and it has been pressure bled many times so there are no air bubbles.

It seems to shift fine at either friction zone, but it's difficult to ride/shift efficiently because I never know where I'll get gear engagement!

Could this be an issue with the actual dry clutch?

Thanks in advance for any help you can provide!
 

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Your problem is caused by the heated fluid being unable to expand back to the reservoir through the master cylinder return port (on the left in the picture).

The causes are:

• Plugged return port

• Ill-fitting aftermarket lever that prevents the piston from uncovering the return port

• Misadjusted piston placement by owner that covers the return port

The lever should have 5% – 10% movement before resistance is felt at the lever.
 
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