Another clutch cylinder question

[jimmyenglish]

So my clutch went flat again and after replacing my slave and rebuilding the master again (last rebuild was only 9 months prior) I realized my problem is that the plunger is not returning all the way because it's binding in the bore. Has anyone else experienced this? Can I lightly sand the top part of the bore where it's binding or should I just give up on it and find another? Thanks everyone. Great forum!

[bongobobny]

Your best bet would be to hone the bore ands try again. Sears online has a set of small hones that will work on that small diameter...

[Squeeze]

Bore size should be 5/8 "

[Condor]

So my clutch went flat again and after replacing my slave and rebuilding the master again (last rebuild was only 9 months prior) I realized my problem is that the plunger is not returning all the way because it's binding in the bore. Has anyone else experienced this? Can I lightly sand the top part of the bore where it's binding or should I just give up on it and find another? Thanks everyone. Great forum!

 

When the master is disassembled can you actually feel the binding?? Or when looking down into the reserve is the rubber cup visable in the larger hole at the bottom, or can you only see the large threads of the plunger?? If you've located the bind area sanding the upper part of the bore shouldn't hurt anything as long as it's behind the rubber cup's rest position. If you can pin point the blem, just dress it with a fine file. I wouldn't bother honing it....

[jimmyenglish]

I definitely can't see the rubber cup, just the threads. Unless I push it back in from the other end. Looking into the bore I can't see any irregularities. Thanks for the input!

[GeorgeS]

In the bottom of resovoiur, there are TWO, Small Holes !!! Are they BOTH, Clear ???????

[jimmyenglish]

Yes. Crystal clear. With reservoir empty (lubed with fluid still) the plunger will not return all the way. it sticks at least half inch from where it should rest. I've had it apart 5 times now. Tried doubling up the spring, twisting the plunger. It bleeds fine but I have 2 inches of play and 1/2 inch of usable clutch. It makes sense how in the past as the bike would warm up, the fluid warms up and would push the plunger back. Then the clutch felt normal. This has been happening a long time. I think a quick honing should do the trick. I'll look at sears.

Edited February 25, 2010 by jimmyenglish

[jimmyenglish]

So I lightly sanded the bore with my dremel. Seemed to clear things up a little. The other part of the problem is that I had too strong of a spring on the actuating pin. I cut it down a little and now everything seems ok. Thanks for all the input everybody!