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Author Topic: clutch lever maintenance...  (Read 1689 times)
hubcapsc
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Posts: 16769


upstate

South Carolina


« on: September 10, 2019, 02:34:25 PM »

I'm freshening up a few things on The Log Truck... I fixed the
brake-light-no-tail-light problem (a fuse) yesterday.

Now I'm going to fix my floppy clutch lever...



I have a salvage clutch master cylinder that I'm fooling with along with the "real" one
on The Log Truck, that's why you see some extra parts here... on an OEM lever (The Log Truck
apparently has aftermarket levers) the big brass bushing shouldn't even come out - there's
no replacement part for it in the fiche. I've had a new chrome Hondaline lever set for 10 years, so
I'm finally going to use them. The smaller brass bushing is what the pushrod (there's two
pushrods in the picture) swivels on as it pushes in the master cylinder internals when you pull
the clutch lever. Those are in the fiche, you can see my old one and my new one. Gordon gave
me the new one Smiley ... the workings of the pushrod and whatever lube might be on it are protected
by the bootie you see there... the bootie on The Log Truck and on my salvage master cylinder are
both toast. You can see what looks like a square-section O-ring in the groove on one of the pushrods.
I think that is really the top of the bootie (I've ordered a couple more booties). Can anyone verify
that the square-section O-ring and the bootie are really the same part?



I've got a big pile of parts here, I think I'm going to rebuild the forks and change out the
alternator and install my Josh headlight harness and maybe put on new timing belts...
I wish I knew someone around here who I thought would do a good job on checking
my valve adjustment, I'm more comfortable with fiddling around with the rolling stock
than looking inside the engine...

-Mike "no one's looked in there in 80,000 miles"
« Last Edit: September 10, 2019, 02:36:28 PM by hubcapsc » Logged

The emperor has no clothes
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« Reply #1 on: September 10, 2019, 02:57:40 PM »

Yes, it's just one rubber boot. Put a little grease inside of the brass cup when you put her back together.  cooldude
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MarkT
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VRCC #437 "Form follows Function"

Colorado Front Range - elevation 2.005 km


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« Reply #2 on: September 11, 2019, 05:58:53 AM »

Yes, it's just one rubber boot. Put a little grease inside of the brass cup when you put her back together.  cooldude

Yep I used the same moly grease I use for the splines so it would stay in place and be super-slippery.
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Vietnam-474 TFW Takhli 9-12/72 Linebckr II;307 SBW U-Tapao 05/73-4
hubcapsc
Member
*****
Posts: 16769


upstate

South Carolina


« Reply #3 on: September 11, 2019, 10:39:45 AM »

The bootie came today. I just ordered it yesterday. The dog noticed something
was going on out in the yard, so I went out and there were some boxes. I heard
a helicopter too Smiley but as I walked further up the trail I saw the delivery truck,
they're not using helicopters (yet)...

The boot looks like Abe lincoln's hat!



I cleaned the snot out of the area around the cup, filled the cup with that blue
BelRay waterproof grease and put it all back together... the hole in Abe's hat-top fit into the
pushrod groove and now I can see how it keeps the grease in and dirt out...



The lever is no longer floppy, it feels great. I put some teflon lube under the throttle
tube, so that side feels great too. I guess I'll go to bleeding the clutch fluid and front
brake fluid next and put on some new front brake shoes... I just got a call from
the Suzuki guy, my Cobra Chrome tire$ just came in. They would have been $400 or so,
probably plus tax and maybe plus shipping,  if I got them on the Internet. I got them for $420
plus tax from the Suzuki guy. I'll take the front wheel over while I'm working with the
brake calipers...

-Mike

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hubcapsc
Member
*****
Posts: 16769


upstate

South Carolina


« Reply #4 on: September 11, 2019, 02:56:08 PM »


Josh headlight harness

D'OH... BonS made the harnesses and Josh makes the LED
retrofit...

-Mike "I got the harness at the Morganton InZane I think..."
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