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[ultrafxr]

We are heading to the GTG in Ouray and leaving Albuquerque for Santa Fe we rode the Sandia Crest Byway to the crest - elevation 10,679 feet.  I'm riding two-up and pulling my fully loaded Bushtec.  No problem at all until near the top as I shifted I had almost not resistance in my clutch lever.  Then I realized that it was not working and I could not shift.  I came in to the parking lot in 2nd gear and braked until the engine died.  While braking I also discovered that I had no rear brake.

After a half hour or so we started back down and everything was working just fine so I'm pretty sure the heat from the exhaust caused the fluid in both my clutch line and my brake line to boil and render the controls inoperative.  Thank goodness I still had front brake!

This has never happened before and I rode this same bike up Mount Evans at over 14,000 feet a couple years ago, but without the trailer.  I'm thinking the additional weight made the engine work harder and contributed to the problem

[grc]

I think you're right.  Even virgin fluid will boil when the temp gets high enough, but if there is any moisture in the fluid it depresses the boiling point.  With the engine working hard on a long climb, exhaust temps would be elevated, and unfortunately Harley hasn't effectively shielded the hydraulic lines for the clutch and rear brake.  For those who have this problem, I'd recommend using the highest boiling point glycol based (not silicone) fluid they can buy, which is currently DOT 5.1, and change it every two years like the manual calls for.  In addition, it would be a very good idea to insulate and/or shield the hydraulic lines where they come into close proximity to the exhaust system.  I'm not sure what's available to accomplish that, and I certainly haven't seen anything offered as a kit for instance, but I assume one could find some kind of pipe insulation product could be applied to the lines.

Jerry

[RedEagle]

Wow!!
I am glad you are OK and are on the road.
Thanks for the heads up!!
Ride safe and keep us posted!

[sadunbar]

We are heading to the GTG in Ouray and leaving Albuquerque for Santa Fe we rode the Sandia Crest Byway to the crest - elevation 10,679 feet.  I'm riding two-up and pulling my fully loaded Bushtec.  No problem at all until near the top as I shifted I had almost not resistance in my clutch lever.  Then I realized that it was not working and I could not shift.  I came in to the parking lot in 2nd gear and braked until the engine died.  While braking I also discovered that I had no rear brake.

After a half hour or so we started back down and everything was working just fine so I'm pretty sure the heat from the exhaust caused the fluid in both my clutch line and my brake line to boil and render the controls inoperative.  Thank goodness I still had front brake!

This has never happened before and I rode this same bike up Mount Evans at over 14,000 feet a couple years ago, but without the trailer.  I'm thinking the additional weight made the engine work harder and contributed to the problem

Jerry...  We ride the Rocky Mountains most every year for a couple weeks each trip and have done so for several years.  Always two up and pulling the Bushtec.  Our first year doing this, I had the exact same thing happen - lost the rear brake and clutch.  Fortunately I always care a bottle of brake fluid and proper wrenches on long trips, so I was able to bleed both systems and carry on.  GRC is right.  The combination of elevation and any moisture at all, will dramatically lower the boiling point of the fluid.  And pulling the mountains brings heat, for certain.  Don't be surprised if you experience some pinging also.  I have since added insulation to both the clutch and brake line, and always flush the systems with new fluid before each trip.  The insulation is a 3/4" high temp sleeve (I believe I purchased it from either Jegs or Summit).  I've not had a problem with fluid boiling since...

[sadunbar]

We are heading to the GTG in Ouray and leaving Albuquerque for Santa Fe we rode the Sandia Crest Byway to the crest - elevation 10,679 feet.  I'm riding two-up and pulling my fully loaded Bushtec.  No problem at all until near the top as I shifted I had almost not resistance in my clutch lever.  Then I realized that it was not working and I could not shift.  I came in to the parking lot in 2nd gear and braked until the engine died.  While braking I also discovered that I had no rear brake.

After a half hour or so we started back down and everything was working just fine so I'm pretty sure the heat from the exhaust caused the fluid in both my clutch line and my brake line to boil and render the controls inoperative.  Thank goodness I still had front brake!

This has never happened before and I rode this same bike up Mount Evans at over 14,000 feet a couple years ago, but without the trailer.  I'm thinking the additional weight made the engine work harder and contributed to the problem

You might want to find a place to flush both systems with new fluid before you continue to far in the mountains...  Even though function has returned, once fluid has boiled, it is much more likely to boil again as the boiling point is now much lower than before....   

[chaos901]

I have had my clutch stop working because of the heat before, stuck in traffic on a trip and such.  But just to be sure, check the level of the fluids to make certain that they are not over filled.  If they are there and the fluid expands when hot it will not allow the piston in the master cylinder to return all the way. 

Curious about that sleeve, may try to find some of that.

[sadunbar]

I have had my clutch stop working because of the heat before, stuck in traffic on a trip and such.  But just to be sure, check the level of the fluids to make certain that they are not over filled.  If they are there and the fluid expands when hot it will not allow the piston in the master cylinder to return all the way. 

Curious about that sleeve, may try to find some of that.

This is the stuff I used...  On both the brake line and clutch line...   

The 3/4" tubing fits over the fittings, and creates an air gap, which aids in the heat protection...

http://www.jegs.com/i/Thermo-Tec/893/18075-10/10002/-1

[ultrafxr]

Thanks all. At Santa Fe HD right now having things flushed.  Hopefully this will prevent recurrence. My co-rider tends to get VERY upset when any type of malfunction occurs.  Fortunately from what I learned from the great folks on this forum I knew exactly what had happened. Otherwise I might have gotten upset, lol!


Sent from my iPhone using Tapatalk

[Chains]

Glad you got stopped and back down to a dealer.  Hope the rest of the journey is trouble free. Going to look into the sleeves Sadunbar used and put on my bike as a precaution.

[ultrafxr]

Kudos to Santa Fe H-D. We were out riding all day and I pulled in at 4 pm.  They flushed clutch and both brakes for $113 in and hour and a half and washed the bike.  Wow, now that is service.  Service writer Eddie was just great.