Hello All from Mobile, Alabama! FJ1200 Owner Here

[lumberjack2277]

  I ride in from the Bay City of Mobile, AL.  I recently bought my first FJ from a friend, and have loved it soo far!  I have a few issues dealing with the clutch master cylinder/slave cylinder, and came across this wonderful site from a Google Search!  Thanks everyone who dedicates their time and efforts into helping out all of the many FJ owners and lovers!

[Steve_in_Florida]

Welcome!

I looked at rebuilding both master cylinders on my 1990 FJ, but was dismayed at the amount of corrosion I encountered.

Brand new units are available from Yamaha. I believe I paid $85.00 for a front brake master cylinder and $97.00 for a clutch master cylinder. Peace of mind and no rebuilding necessary. Bolt, bleed and GO, BABY, GO!!!

Some of the guys on here may have leads to new units for even less.

[FJmonkey]

Lumberjack, your first post. Welcome and yes...We offer the the most useful (and not so useful) advise on all years of FJ11/12 bikes (and non-FJ bikes) and damn near anything for that mater. How long have you had your FJ? What year is it? What kind of riding do you do? Welcome to Kookaloo. Look it up, you need to know it if you want to be an FJ owner...

[craigo]

Oh, he's a lumberjack and he's OK....   (sorry, couldn't resist)

Anyway, if you have a 89-93, it's a simple matter for you to invest in a  14mm master off a multitude of bikes and install that instead.  Then pick up a set of R1/R6 bluespots and just bolt them on the forks.  And use new crush washers.

You will not believe the difference.

Welcome,

CraigO

[racerman_27410]

Welcome to the group! 

good advise already given.... my.02 is take the opportunity to upgrade! 
 


KOokaloo!

[1tinindian]

Oh, he's a lumberjack and he's OK....   (sorry, couldn't resist)

Anyway, if you have a 89-93, it's a simple matter for you to invest in a  14mm master off a multitude of bikes and install that instead.  Then pick up a set of R1/R6 bluespots and just bolt them on the forks.  And use new crush washers.

You will not believe the difference.

Welcome,

CraigO

Monty Python, excellent! LOL!

Welcome lumberjack...do you listen to Jackyl??
Nevermind us, if we can't have humor, what's the point, right?

Let's see some pictures of the FJ and what you plan on doing with it.
Agreed, update the stock parts with later model pieces and unleash the mod-monkey!

Leon

[rktmanfj]

...do you listen to Jackyl??

Have that one, play it often...

Welcome, Lumberjack!

Jackyl - The Lumberjack

[racerman_27410]

HOly crap i had forgotten (thankfully) about that song.

Chainsaw as a musical instrument...... i dont really think so.


chainsaw + a big tree to fell?    absofrickinlutely!



KOokaloo!

[lumberjack2277]

 LOL!!  I chose Lumberjack2277 as my name on here due to me and my wife owning a Tree Service and Land Clearing Business. I thought of that ole' song as I was creating my account as well!!     I've owned probably 30 bikes are so... Busa's, Stretched Ninja's, blah ba blah!  BUT, my friend who knew I always loved bikes called and said he was selling his 1989 FJ1200.   It has a unique aftermarket color scheme that someone slapped on it at some point or another!   It runs and rides great, but the Clutch Master is the first to be tackled due to maintenance needs.  It was getting very spongy.

  When it comes to riding, i've done everything from long distance cruising to strapping my wrists into a built KZ turbo drag, but Igot this bike just for vme and the Mrs to do some riding together, again.  Plus, I got it at a really nice Price!   

[Flyover Country Joe]

Lumberjack,
   Love the yellow paint! Yamaha's can't look bad in yellow and black. Welcome to the campfire..........

[racerman_27410]

i would just about bet its the slave cylinder giving you the mushy clutch.

these bikes are uber reliable but if we've seen one slave cylinder fail we've seen a hundred.... all from lack of regular fluid changes.

I've seen seal kits work and i've seen slave cylinders that were pitted badly so if it were me i would just get a new slave cylinder, bolt it on, bleed and go.

regular fluid changes will keep it in good nick for a long time... i change all my hydraulic fluid (brakes,clutch and fork oil) at least every two years.




KOokaloo!

Frank

[lumberjack2277]

  I would have first thought the slave cylinder as well, but I pulled it first, and it had no signs of leakage.
      Then I pulled the clutch master cylinder, and removed the handle.  I didn't even need to remove the circlip... it all just fell out into my hands!
     I cleaned the parts, put in a new rebuild kit, and its just not doing the job.  I can hold the lower hose end between two fingers (the slave cylinder end) and squeeze away all day long, and hold the pressure all in with barely much force holding it tight with my fingers.  You'd think after a pump or two, it'd spray all over?!??!   
   Also, up top the fluid level just won't drop by pumping of the lever, even with the bottom slave bleed all the way open.  I couldn't even drain the unit even with a new rebuild kit installed, by pumping it with the bleeder out!    It just churns the fluid in the reservoir.

  If its anything other than my master cylinder, i'll be shocked.   And this fluid has never been changed by the looks of it. 

[racerman_27410]

Bleeding the master cylinders can be tough at times but if it fell apart on you it may just be too far gone .... as you have already determined.



KOokaloo!

[moparman70]

Hello and welcome - as they all said lots of info here. 

As for the bleeding - clutch wise I have only bled mine the normal way but it took a few attempts to get it fully bled.  I did upgrade to the blue dot calipers ( look under mods section for more info) and found the best way to bleed the front was to "reverse bleed" .  Initially, by pumping the handle I was getting nowhere ... like you said after a few pumps you should see the fluid drop but that was not happening.  I was getting a little movement but not to the degree I should.  Then it was suggested to push on the caliper pistons themselves -- so I removed the calipers from the mounting screws and pushed on the piston --- and it worked.  A huge amount of bubbles pushed out through the master cylinder.  I did it to both sides and then installed the assy.  Added fluid and then used the handle to complete the bleeding. 

I don't know if you can do the same to the clutch but if you can push back on it .. it might help get rid of the stuck air bubbles.

I think CraigO gave me the tip on the reverse bleeding -- thx -- and the new crush washers too.

stevecc

[lumberjack2277]

 I removed the slave cylinder and pushed it in, sending all air up to the top.  I tried several attempts to bleed, in various ways lol!  I had a good friend who works at the local Yamaha shop come by after church today to look over everything (i'm DYING to ride now lol).   He came to my conclusion... too much inner wear to get a good piston seal on the inside of the master cylinder.
     It's basically bypassing the piston, and just churning the fluid inside the reservoir. I ordered a updated master cylinder on Friday night, so the delivery day of Tuesday just can't come quick enough!

   Once I get the clutch back to operation, i'll ride the Mrs around for a few days, then snatch the front tubes to put in new fork seals.  I've been reading up on updated progressive springs, so i'm going to go with them with the new kit rebuilds.  THEN...  snatching carbs to try and fix my 3500 rpm dead/flat spot.  ;-)