Clutch master cylinder overhaul #5

Regarding the clutch master cylinder which I repaired the hole at piston with solder, one of my friend advised me that the solder might not be hard enough. Therefore, I tried the repair again in another way.

Disassembled the clutch master cylinder again.

Now I can do it very quickly because I disassembled brake master and clutch master cylinders many times J

Heated and removed the solder at the piston hole.

I used the soldering iron instead of the burner because I heard giving too much heat on piston should be avoided.

In this time, according to the advice from my friend, the repair method is to screw in the thread with strong adhesive into the hole, then grind the thread head to make the piston surface flat. In order to do it I bought bolts and a grinding stone at the hardware store.

Cutting the bolt to adjust the length to fit the hole depth.

Engrave the minus groove at the cut bolt head to make screwing in possible with minus screw driver.

It took time, but the result was not bad.

Paste the JB weld in the piston hole.

And screw in the cut bolt with minus screw driver.

Then, grind the bolt and piston with the grinding stone.

Using power drill,

Grind, grind, grind….

It took longer time than I expected to make the piston and bolt becoming flat. Steel is much harder than solder.

I reassembled the clutch master cylinder right away.

I believe finally the overhaul of my clutch master cylinder has finished!

(My original blog was written on 28th Jul. and 2nd Aug. 2009)

Comments

Tip to repair rubber parts

I disassembled the rear axle before. There had been no progress on it because I started the repair of the fuel tank during my summer holiday. While painting the fuel tank , I repaired the torn rubber boot of the parking brake wire. I guessed it didn ’ t cost high because it was small rubber part. But I wanted to try the repair method I read on the magazine article before. This was the condition before the repair. The rubber was torn apart and separated almost. I used this self-adhesive type butyl tape. I pasted lots of small pieces of the butyl tape on the back side of the rubber boot. As time goes by , these tapes would melt and stick together. After this I applied plenty of adhesive “ Super X Black ” on the rubber boot. On the magazine of MOTO MAINTENANCE , I read the article that the motorcycle seat was repaired with this method. So , I wanted to try it. After drying 1 day , it became like this....

Clutch master cylinder overhaul #2: tough match

I disassembled the removed clutch master cylinder. And I found that the piston was heavily rusted. I tried to hit it with a hummer , Pushed the piston using the vise clamp like this. However , the piston was heavily sticking by rust and it could not to be moved today. The brake master cylinder was replaced in the past , however , the clutch master cylinder was not. Therefore , the condition of the clutch master cylinder might be worse. Tentatively , I would spray the rust-penetration lubricant from both sides of the piston and try again in a few days. If it doesn ’ t work , I would give up the overhaul and order the new part. ( My original blog was written on 2nd July 2009 )

Clutch master cylinder overhaul #3

I was still struggling with the sticking piston of the clutch master cylinder. I thought I should give up and look for the new part for the replacement. And to for my curiosity , I started to destroy and disassemble the clutch master cylinder piston by drilling. When I was drilling the piston halfway , I didn ’ t have any specific idea , however , I thought to tap the piston to make the thread. I started to turn the tap handle , and I felt the feeling that the piston was moved. So , I tried to pull it , and then suddenly the piston was removed from the cylinder. Finally I could extract the rusty piston! I observed the extracted piston. It looked there was no risk of the leakage of the fluid because the hole I made in the piston was not penetrated. Thinking the function that this part only holding the rod connected with the clutch pedal , it could be reused if the hole would be filled by the hard material. However , be...

The day my "onboro ALFA" would revive

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