That tricky clutch clunk clunk

[Old Rider]

So on my 1986 FJ1200 I have tried to repair my clutch :Symtoms are heavy clunck sound when shifting gears.As if i cant engage the clutch enough.
Here is what i have done so far: rebiult the slave sylinder (it was not leaking but replaced the seals anyway.)
there was some scoring and i used 1200grit paper and cleaned the cylinder and piston. got ok exept for one scratch i did not got completely sanded down.
I have bleeded the clutch 3 times and yes got all bubbles out with the bike on centerstand and reservoir higest point and some knoking on the pipes and the handle tied up ets.

I have noticed tht the bleed screw is badly worn ,can it draw air in thru the threads?
also yesterday i had a look at the master cylinder and clutch lever handle.The handle is badly worn at the contactpoint with the pushrod.The bushing that sits in the hole in clutch lever handle seems very worn and got a oval shape.It also have a hole right thru it.Is that normal?
The seals in the mastersylinder where the pushrod goes in is blown and dry and the pushrod is rusty.
So do you think that the worn out components in the mastercylinder/clutch lever handle can make the clutch not engage enough?
Also suspect that im missing the metal ball sitting at the end of pushrod in engine is there any way to check if its missing?

[racerrad8]

Yes, the wear on the clutch bushing and subsequently the lever is normal. That will also create the issue you are describing.

That is why I stock replacement clutch levers and the brass pivot bushing.
http://rpmracingca.com/proddetail.asp?prod=M%2FC%3AClutchLever

http://rpmracingca.com/proddetail.asp?prod=M%2FC%3AClutchLeverPivot

I also stock new bleed screws for the slave cylinder.

http://rpmracingca.com/proddetail.asp?prod=36Y-W0098-00

Randy - RPM

[chiz]

After messing around for ages with various bits and tricks...I found some used parts on the www. It is not until I changed my slave and master for ones that ended up being a good one first time sheer luck that the system worked well and no leaks. Although I had been the seal replacement rout a number of times on the original bits with NO JOY.
Lez

[rktmanfj]

Also suspect that im missing the metal ball sitting at the end of pushrod in engine is there any way to check if its missing?

No need to check... If it were missing, your clutch wouldn't work at all.     

[red]

So on my 1986 FJ1200 I have tried to repair my clutch :Symtoms are heavy clunck sound when shifting gears.As if i cant engage the clutch enough.  Here is what i have done so far: rebiult the slave sylinder (it was not leaking but replaced the seals anyway.) there was some scoring and i used 1200grit paper and cleaned the cylinder and piston. got ok exept for one scratch i did not got completely sanded down.  I have noticed tht the bleed screw is badly worn ,can it draw air in thru the threads?  i had a look at the master cylinder and clutch lever handle.The handle is badly worn at the contactpoint with the pushrod.The bushing that sits in the hole in clutch lever handle seems very worn and got a oval shape.It also have a hole right thru it.Is that normal?  The seals in the mastersylinder where the pushrod goes in is blown and dry and the pushrod is rusty.  So do you think that the worn out components in the mastercylinder/clutch lever handle can make the clutch not engage enough?  Also suspect that im missing the metal ball sitting at the end of pushrod in engine is there any way to check if its missing?

Old Rider,

In order:
Man, replace that scored slave cylinder!  Randy at RPM can fix you up. 
Use a tiny dab of High Temperature RTV on the NEW bleeder screw threads.  Amazon has it:
https://www.amazon.com/Permatex-82180-Maximum-Resistance-Silicone/dp/B0002UEN1U/ref=sr_1_4?ie=UTF8&qid=1471793687&sr=8-4&keywords=permatex+high-temp+RTV
Replace the worn-out clutch lever and bushing; nothing lasts forever.  Lube these new parts, and they will last longer. 
I would doubt that the pushrod ball is missing.

Cheers,
Red

[Old Rider]

Yes, the wear on the clutch bushing and subsequently the lever is normal. That will also create the issue you are describing.

That is why I stock replacement clutch levers and the brass pivot bushing.
http://rpmracingca.com/proddetail.asp?prod=M%2FC%3AClutchLever

http://rpmracingca.com/proddetail.asp?prod=M%2FC%3AClutchLeverPivot

I also stock new bleed screws for the slave cylinder.

http://rpmracingca.com/proddetail.asp?prod=36Y-W0098-00

Randy - RPM

Thanks for links and tips i will order some parts soon.

[Old Rider]

After messing around for ages with various bits and tricks...I found some used parts on the www. It is not until I changed my slave and master for ones that ended up being a good one first time sheer luck that the system worked well and no leaks. Although I had been the seal replacement rout a number of times on the original bits with NO JOY.
Lez

Good news you got it fixed at last seems i have to replace some parts.

[Old Rider]

Also suspect that im missing the metal ball sitting at the end of pushrod in engine is there any way to check if its missing?

No need to check... If it were missing, your clutch wouldn't work at all.     

Thanks for the information then i can rule out that 

[Old Rider]

So on my 1986 FJ1200 I have tried to repair my clutch :Symtoms are heavy clunck sound when shifting gears.As if i cant engage the clutch enough.  Here is what i have done so far: rebiult the slave sylinder (it was not leaking but replaced the seals anyway.) there was some scoring and i used 1200grit paper and cleaned the cylinder and piston. got ok exept for one scratch i did not got completely sanded down.  I have noticed tht the bleed screw is badly worn ,can it draw air in thru the threads?  i had a look at the master cylinder and clutch lever handle.The handle is badly worn at the contactpoint with the pushrod.The bushing that sits in the hole in clutch lever handle seems very worn and got a oval shape.It also have a hole right thru it.Is that normal?  The seals in the mastersylinder where the pushrod goes in is blown and dry and the pushrod is rusty.  So do you think that the worn out components in the mastercylinder/clutch lever handle can make the clutch not engage enough?  Also suspect that im missing the metal ball sitting at the end of pushrod in engine is there any way to check if its missing?

Old Rider,

In order:
Man, replace that scored slave cylinder!  Randy at RPM can fix you up. 
Use a tiny dab of High Temperature RTV on the NEW bleeder screw threads.  Amazon has it:
https://www.amazon.com/Permatex-82180-Maximum-Resistance-Silicone/dp/B0002UEN1U/ref=sr_1_4?ie=UTF8&qid=1471793687&sr=8-4&keywords=permatex+high-temp+RTV
Replace the worn-out clutch lever and bushing; nothing lasts forever.  Lube these new parts, and they will last longer. 
I would doubt that the pushrod ball is missing.

Cheers,
Red

Thanks for links that high temp silicone gasket ill try when installing