92 FJ1200 Clutch

[PGH STEEL 66]

Hi All,  Just rebuilt and bled the clutch master cyl. and slave cyl. and clutch won't disengage. Removed slave and pulled in clutch lever and piston moved a bit. Anyboby know how far it's supposed to move. Any other ideas will be greatly appreciated. Thanks!

[FJmonkey]

Make sure item #3 is not in backwards, DAMHIK  And don't start the engine with the clutch slave off. Your cat will thank you.

http://www.ronayers.com/oemparts/a/yam/50043252f8700209bc78b255/front-master-cylinder-2

[Pat Conlon]

Also, since you squeezed the lever with the clutch slave off....you will need to open the bleed port on the slave and push the plunger back with your thumb, then, while holding the plunger back, close the bleed port.

Don't reinstall your slave until you do this or your lever will be rock hard.

[Earl Svorks]

   Hey Pat,
  If there is any need to open the bleed screw in this circumstance, it would indicate that the compensating port hole in the MC would be plugged up ,or a lack of free play between the clutch lever and the plunger,thus the primary cup has covered the little hole in the bore of the MC.
   Cheers
   Simon

[Pat Conlon]

Hi Simon, you are correct. Good point. If you can not push in the slave plunger without opening the bleed port, the relief port in the m/c is plugged.
I just find it easier to open the bleed port rather than pushing all that fluid up to the m/c..

However, the easiest way is not to squeeze the clutch lever when the slave is off....

[Earl Svorks]

    When and if I have the need to remove the clutch slave cylinder, providing I do not intend to open the hydraulics, I prefer to use a slightly different method to secure the cyl. Immediately after I unbolt and remove the slave, I pull the lever to the grip and secure it there. This prevents any movement, accidental,or otherwise and it seals the hydraulics . There is no risk of air getting in ,or fluid getting out.
You could leave it like this for a month without anything changing. No need to release the lever until it's time to bolt the slave back on.
     Cheers
     Simon

[FJ1100mjk]

Immediately after I unbolt and remove the slave, I pull the lever to the grip and secure it there. This prevents any movement, accidental,or otherwise

However, the easiest way is not to squeeze the clutch lever when the slave is off....

You two need to get on the same page.

[Pat Conlon]

Why squeeze the lever? Just because you can? Worried about air getting into the system?

Nope, sorry Simon, I just disagree. I have a wood block I put between the lever and grip just to prevent that from happening. I do the same thing when my brake calipers are off.

I take the ignition key out of the bike put it in the house before I take my clutch slave off....same reason.

Lately is seems that I've been spending a longer amount of time looking for a tool I've misplaced.
"I know that 12mm socket is here....somewhere...I just used it."
A week later my wife says... " Look what I found in the washing machine...."

[aj52]

A week later my wife says... " Look what I found in the washing machine...."

Happens to me too,luckely never ended up in washing machine

[ribbert]

Immediately after I unbolt and remove the slave, I pull the lever to the grip and secure it there. This prevents any movement, accidental,or otherwise

However, the easiest way is not to squeeze the clutch lever when the slave is off....

You two need to get on the same page.

Even better, remove it.

Front levers are exposed to road grime and can generally be found in one of two states. Still with grease but so impregnated with grit it is closer to valve grinding paste, or the more common one, dry with a fine black powdery residue. Neither one is good and makes them stiff to use under load and promotes wear.

Take the opportunity of removing the slave to remove the lever and clean and lubricate it, you will feel the difference. This is a job not on many people's radar and should be done regularly.

Noel

[Pat Conlon]

Absolutely spot on   Very good Noel!

Although with me, I'll have to remember to reinstall the lever *after* I put the slave back on....

To squeeze, or not to squeeze, is not really an issue. My point is, if you do squeeze, just remember to push back the slave piston before you reinstall.

[fnlyafjat51]

Why squeeze the lever? Just because you can? Worried about air getting into the system?

Nope, sorry Simon, I just disagree. I have a wood block I put between the lever and grip just to prevent that from happening. I do the same thing when my brake calipers are off.

I take the ignition key out of the bike put it in the house before I take my clutch slave off....same reason.

Lately is seems that I've been spending a longer amount of time looking for a tool I've misplaced.
"I know that 12mm socket is here....somewhere...I just used it."
A week later my wife says... " Look what I found in the washing machine...."

I just did that with my 10mm wrench last week, except I forgot where I found it. I think it was like 4 drawers off in the top with all the misc. crud. I think.  Looked for it for 4 or 5 days. Had to use an old crappy one until I found it. 

[rlucas]

I just did that with my 10mm wrench last week, except I forgot where I found it. I think it was like 4 drawers off in the top with all the misc. crud. I think.  Looked for it for 4 or 5 days. Had to use an old crappy one until I found it. 

You've only got one 10mm wrench?

Amateur.

[fnlyafjat51]

Had 3, but lost one, so I'm down to 2. Have 3 11's, 3 12's, 3 13,s, 4 14's, 15, 3 17's, 18, 2 19's, 20, 21, 22, 23, 24, and I think a 36 or 34, and I think another one time use, odd size wrench. Dang memory. Plus all the small stuff in there like 5-9's. we won't go into the large one time use sockets, or modified to fit sockets and home made tools like a clutch spring compressor for a ford c-4 trans. Guess it's time to hit the swap meets again and restock. lol
Oh, and my 1 1/4 3/4 drive socket with 3/4-1/2 adapter to take the drum out of the washer to replace the seal. lol

[Pat Conlon]

My problem is focus. I focus so much on the part I've removed, and who knows where I put the tool I used to remove the part.

No big deal except I find the problem getting worse.