Clutch slave cylinder rebuild maintenance

[Old Rider]

I'm planning to do some service on the clutch slave and the clutch master cylinder on my bike soon and while waiting for the repair kits that is ordered to arrive in post i had a look at another old slave cylinder unit i have laying here that was replaced some years ago.I knew it was leaking and had
rust innside but decided that i will try to see if it is possible to save it by a little honing and fixing.
Made a write-up that may be useful for some thinking of doing this.

[T Legg]

Nice work and all done before your wife returned .
If one day new parts are no longer available your bike will probably be one of the last still on the road.

[Greenlander]

Nice work and all done before your wife returned .
If one day new parts are no longer available your bike will probably be one of the last still on the road.

nice and informative presentation. I assume you didn't do this rebuild in the kitchen while your wife is out running errands  . Anyhow I just finished rebuilding the master cylinder on my 84 FJ with the kit from RPM. Didn't come with copper washers so I used the old aluminum ones I took off. No good! Allowed a tiny bit of a it to get sucked in but it felt firm and shifted properly. So I rode it to work and when getting to the first traffic light after 20 min ,I could barely get in neutral.Diagnosed the problem and got new copper washers from local shop.
Then realized my clutch lever is so worn at the contact point from almost 40 years that it barely activates the clutch. Called RPM but no replacement available. So I JB welded a 8mm hex nut on and it works good
How long? Will keep you posted

[Old Rider]

Nice work and all done before your wife returned .
If one day new parts are no longer available your bike will probably be one of the last still on the road.

You might be right 

[Old Rider]

Nice work and all done before your wife returned .
If one day new parts are no longer available your bike will probably be one of the last still on the road.

nice and informative presentation. I assume you didn't do this rebuild in the kitchen while your wife is out running errands  . Anyhow I just finished rebuilding the master cylinder on my 84 FJ with the kit from RPM. Didn't come with copper washers so I used the old aluminum ones I took off. No good! Allowed a tiny bit of a it to get sucked in but it felt firm and shifted properly. So I rode it to work and when getting to the first traffic light after 20 min ,I could barely get in neutral.Diagnosed the problem and got new copper washers from local shop.
Then realized my clutch lever is so worn at the contact point from almost 40 years that it barely activates the clutch. Called RPM but no replacement available. So I JB welded a 8mm hex nut on and it works good
How long? Will keep you posted

Yes i did most of the work when dragon not at home  
I know exactly what you are talking about when it comes to worn clutch lever i post a pick of mine before i had to replace it there is a hole right thru it in the brass bushing and it is deformed.I also used washers to take up the slack.And about the copperwasher i think it is
crucial to use new/good ones on the banjobolt the threads can suck in air.I use a little rtv silicone on both bleeder screw and banjobolt

[T Legg]

Then realized my clutch lever is so worn at the contact point from almost 40 years that it barely activates the clutch. Called RPM but no replacement available. So I JB welded a 8mm hex nut on and it works good
How long? Will keep you posted

[/quote]

I had the same problem with the clutch handle on one of my 84's a couple years ago . My local Yamaha dealer has access to company that searches the inventory of all the Yamaha dealers and found a shop that had two handles in stock. I bought them both and used one so far. They may have been the last two in existence but there could be more out there. I am saving my old handles in case someday I need to either have the divots in them welded or try something like you have done.

[T Legg]

The clutch handle on the fj1100's are different I think.

[5speed]

great write up. rebuilding the slave, clutch and brake master cylinders are on my to do list this winter or spring.
you should have been here the day my wife caught me with the tractor tire in the bathtub looking for a leak..

[red]

great write up. rebuilding the slave, clutch and brake master cylinders are on my to do list this winter or spring.
you should have been here the day my wife caught me with the tractor tire in the bathtub looking for a leak..  

5speed,

I would have to agree.  You should do that in the swimming pool.   

[Old Rider]

you should have been here the day my wife caught me with the tractor tire in the bathtub looking for a leak..

You should have told here that she should be glad that it was  a tractor wheel and not a woman !

[5speed]

great write up. rebuilding the slave, clutch and brake master cylinders are on my to do list this winter or spring.
you should have been here the day my wife caught me with the tractor tire in the bathtub looking for a leak..  

5speed,

I would have to agree.  You should do that in the swimming pool.   

I would need a pool for that. lol

[Old Rider]

Since i still  was waiting for the postman to arrive with the slave and master rep kits i mounted both the old slave and master cylinders that i have been working on to see if they are working on the bike.You can read about the master rebuild in this tread :  http://www.fjowners.com/index.php?topic=20077.0 At the same time i could start preparing the newest slave and master that was on the bike for the new seals.
.I have ridden the bike for 2 days and had no problems.A little WARNING about the master cylinder is that i would
never try to hone the master cylinder much as i did on a brake master cylinder.The brakes are important and after increasing the diameter in the master bore
the seal might blow under hard braking when you need it at most.The clutch on other hand is not that critical.Anyway the rep kits arrived yesterday so
i started prepping the newest slave and master to install new seals in them

[FJ1200W]

Great write up and even better timing -

Thank you!

[Old Rider]

Great write up and even better timing -

Thank you!

Thanks Steve! I like to read about your wrenching to great stuff 

[Old Rider]

Since i was silly enough to make 2 separate treads one for master and one for slave i post this last update about installation and bleeding in both treads.
yesterday i removed the old master and slave cylinders that had a 2 day testride they worked fine without leaks or any other problems.
I then put back the newest master and slave that has new seals.I primed both the master and slave to make bleeding process go fast