Progress today
Flushed 4 cycles of fresh water through the radiator/hoses/pump loop. On first two runs the water was still quite green from the engine side. All clear, no obvious grit or residue in the water by the fourth. Filled radiator and half of reservoir bottle with fresh 50/50 antifreeze.
Filled clutch master cylinder reservoir and bled clutch line with the Mityvac. Got good strong lever feel, but would not go full travel. Felt like the push rod was not going anywhere.
Pulled slave cylinder from engine, noting the cylinder was out to the edge of the cylinder. Reconnected hydraulic line at the slave and bled again. Used hydraulic pressure with the clutch lever to gently push piston out of the cylinder. It would not move by hand.
Pulled rubber piston seal, found in excellent condition after crusted gunk cleaned out. Polished both the piston and cylinder.
Lubed piston assembly with a little brake fluid, and reassembled. Piston readily moved in cylinder when pushed against the spring.
Reinstalled the slave cylinder and bled the line. Could feel apparent motion against the push rod, smooth lever action, but the clutch does not disengage. Tested statically – tried turning rear wheel while bike in first gear.
Next
Will need more thought, research, testing. May be a good idea to disassemble the clutch and inspect/clean/lube.
PS. Further research shows this seems to be a common problem. Plates may just be stuck together – by time or old oil/sludge. Methods found online to “break” them loose by running engine, shifting into gear. May try that after other systems’ overhauled and the engine is running.