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Help me figure this out.

  • Thread starter Thread starter spyug
  • Start date Start date
Well I have the pressure plate off and have been trying to see the pushrod move. absolutely no luck. I've triple checked the function of the slave and pumped its piston just about all the way out then back in again. The master is hard but I squeeze and no movement at all of the pushrod, yet if I take the slave off and push it with my fingers while feeling the other end I can move it all easy peasy. Its truly bonkers.

As I mentioned, the brain is fried right now so after 4 days of farting around and wasting time I'm done. I think I will rebuild the slave tomorrow and put on the new SS clutch line and see if that gets me anywhere.

I'll let you know what I find.

thanks for all the support my friend.

cheers
Spyug
 
I did change out the old hose for the new ss line and the lever is now rock hard.

The slave still works (piston move out and will push back in by hand) when not fitted to its location on the sprocket cover but once attached it will not activate the pushrod. The pushrod,ball and short pushrod move effortlessly by hand bit don't budge with the slave cylinder in position.

I cannot for the life of me figure this out.

Any ideas my friends?

spyug
 
something somewhere, is being blocked, or misaligned, or something,,,as per the diagram there is nothing to this system, or so it appears....

115_clutch.gif
 
Is there a little spacer between the slave and the pushrod that may be missing? Do either ends of the pushrod look chipped? Maybe see if a thin nut or something to act as a "test spacer"between then rod and the slave piston will yields movement..if so, maybe you need to mod it a bit.

No doubled up gaskets or anything that would impose a gap between the rod and the piston???

How does the end of the release bearing where the rod pushes on it look? Deeper looking worn cupping going on there?? My need a new release bearing shaft??? Is 17 and 18 an adjustment nut arrangement? slack properly taken out???
 
Can we see a picture of the piston side that is supposed to push against the rod? Is there a hole or detent that is supposed to accomodate the rod end? If ther is a detent or cupping on the psiton..is it supposed to actually be there or should it be flat? Is it pushing straight in and not imposing a bind on the pushrod itself as the slave pumps up?
 
Last edited:
Here are some views of the slave as it sits in the sprocket cover. This combo is off the parts engine not the actual one I'm having trouble with. Note the clearance between the piston face and the cover. That would be the limit of piston travel.

100_1114_zps6b12a77c.jpg


You can see the cup in the piston in which the end of the pushrod rides. The end of the pushrod is rounded to fit the cup.

In this one you can see the distance between the piston face and the cover.
100_1115_zpse1cbda02.jpg


In this final one you can see the valve shaped short pushrod that touches the inner face of the pressure plate to activate it. Behind it are the nut and lock washer holding everything to the main shaft.

100_1113_zpsdcdc6c00.jpg


I didn't actually take the sprocket cover off the engine and try the slave cylinder in it to see if I can see any obstructions but I will try that next.

Thanks for your continued interest and support.
 
spyug said:
I did change out the old hose for the new ss line and the lever is now rock hard.

The slave still works (piston move out and will push back in by hand) when not fitted to its location on the sprocket cover but once attached it will not activate the pushrod. The pushrod,ball and short pushrod move effortlessly by hand bit don't budge with the slave cylinder in position.

I cannot for the life of me figure this out.

Any ideas my friends?

spyug
Click to expand...

Did you change the banjo bolts ? Got one without a hole ? Are the new lines clear ?
When you bolt on the slave cyl are you putting a bind on the casting which locks the piston ?
 
Well the mystery has finally been solved.

This afternoon I pulled off the sprocket cover with the slave cylinder in place and unlike the above pictures there was absolutely no gap between the piston and the cover. It was jammed hard against it.That was the Eureka moment.

I realized the piston was not retracting far enough and sure enough while I could move it back by hand about 2 or 3 mm, it wouldn't go back further. Until I put a "C" clamp on it. The piston had gunk and rust holding it at almost the end of its travel and one squeeze brough the piston hard against the case and thus no movement of the pushrod.

So the next assignment is, as I had mentioned, a cleaning and rebuilding of the slave cylinder and the master cylinder too. No point in doing it half-azzed.

A big thanks to all who helped and encouraged me on this. I couldn't have gotten to this with out you.

cheers my friends.

Spyug
 
I thought all you great guys that supported me in this challenge would like to see the mess:

100_1118_zps6da830d3.jpg


100_1116_zpsb23429d5.jpg


It all cleaned up nicely and the seals still look ok so I'll put it back together and try it out.

Well Adrian you were correct again and the silly thing is I could have sussed this several days ago if I had looked at the bunged up slave in its cradle as I had with the ones from the parts bin as shown above. It was so darned obvious.

Well I think I'll finally be able to get an uninterrupted nights sleep tonight, finally.

Thanks again guys I couldn't have done it with out you.

cheers yur pal Spyug
 
Way to go......

Well I certainly know what I will be doing with my FZ......going to tear down everything....and have a good look at it all....

I am sure glad you got it sorted out.....and the boys here came through.....

.
 
Good that you've solved it - probably start on the motor I've got here over the weekend. Come up with a parts list and see what I have to farm out for work...It's going to be raced so at the least I'll be setting the squish correctly as I've never yet found one of these with less than 1.8mm of piston to head clearance...
 
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