Long Clutch Lever

[fj-f3a]

A few weeks ago, on of every FJ owners worst nightmares happened when she fell of the center stand. I was able to cushion the fall.

Some minor scratches to my new top box and the obligatory bent clutch lever were the results.

I straightened the lever as best as possible, but one can never get it perfect and the crazing of the painted finish, so off to purchase two new levers. One as a spare.

Upon removal of the damaged lever, it was obvious that the brass pivot bush would require replacing, so I manufactured a new bush, then fitted one of the new levers.

The operation of the clutch was noticeably different being firmer and longer. I took the bike for a test ride and apart from the higher lever, everything felt fine.

After a week of riding, the high lever was becoming annoying, so I decided to investigate. I realised that with a new brass bush the lever would be higher, but is just didn't feel quite right.

Comparing the old lever with the new revealed no obvious geometrical differences, so I ruled that out.

I removed the slave cylinder and inspected the seal, piston, spring and dust cover. All looked fine. I reassembled the slave cylinder and bled the system. Clutch lever still high and firm.

I do not remember their being a gasket between the slave cylinder and the mounting point on the engine, no need for one, but I thought there may have been and that I had misplaced it, so I placed some washers between the slave cylinder and the mounting point. This had the desired effect of lowering the lever, but it still didn't feel quite right.

During the ride to work that afternoon, I thought about the washers and realised that their use should not make any difference to the operation of the clutch.

Next morning, I removed the washers and proceeded to refit the slave cylinder, but the mounting screws would not reach the mounting holes. Strange. Once again, I disassembled the slave cylinder, checked it, reassembled and refitted. Lever still the same.

The next day, Alan (Sparky84) and I rode to Robertson Pie Shop to meet up with Troy (Troyskie) for a pie (or 2). My bike seemed fine, except for the high lever. However, I did notice that during the extended "higher" speed ride, the lever seemed to become even firmer. This had me stuffed. However, there appeared to be no clutch slippage. I was able to ride home with no apparent problems but I decided not to ride the FJ to work that afternoon, just to be safe.

Thinking about the problem at work, logic dictated that it must be the new lever. But I had already compared the old and new levers. They were geometrically identical.

Next morning, out of frustration, I dismantled the slave cylinder once again, but everything was still fine. Before bleeding the system for the umteenth time, I refitted the old lever. I removed the cap off the reservoir and preceded to bleed the system. While activating the lever, I noticed the fluid spouting from the orifice. "Hang on, I don't remember seeing this with the new lever." (Yes, I have noticed this before when bleeding the brakes) I refitted the new lever an sure enough, no fluid spouting from the orifice. I assessed the situation with the new lever attached and this is what I found.

With the new lever fitted, notice the position of the brass bush, first photo.


Compared to this position with the old lever fitted, second photo.


This was the cause, photo 3 and 4.


This was the fix, photo 5.


This was the result, photo 6 and 7.


The nib and lip were not letting the lever fully release thus preventing the master cylinder piston seal from uncovering the orifice, allowing the system to depressurise and self bleed.

It appears that no damage was caused by this chain of events. The clutch is working fine and there is no slippage. The clutch assy has not been touched in 95,000km.

The lesson to be learnt here is to always check for fluid spouting from the orifices when bleeding the clutch or brakes. This is noticeable in the first inch/mm's of movement.