Hydraulic clutch

[windmill]

Got the slave cylinder today.

It goes between the legs of the retainer where the clutch release lever retainer passes through.

1685049501-picsay.jpg

IMG_20230518_160038923.jpg

And be aware, it's not an X-ring on the cylinder, but 2 tiny O-rings of an uncommon size.

[Trumpetwasher]

Thanks! Explains the "2 O rings" description of the clutch slider:

2012 to 2016; 8.104-03206-01, 2 O-ring, 2_mm........probally 23mm per phughes, need to confirm.

[aduthie]

“Where does this go?”

Yonder, I think! I suspect it could be left out, but haven’t tried to install mine yet.

7867FD26-3722-4DB4-84F3-F446A0D1971E.jpeg

[Trumpetwasher]

Finally decided to go with a premade hose. With any luck, I'll get the clutch assembly switched over tomorrow afternoon.

[Trumpetwasher]

1685845287-picsay.jpg

Do you know how close I was to having this thing on? The cylinder fits the hole (be careful the rod doesn't fall out while you're trying to insert the cylinder), however, the holes in the clamp and the spacer are too small. The pictures show a rod with a cotter pin in it. What the bike has is a shouldered socket head bolt and a nylock nut. Stupid idiot that I am, I didn't measure the bolt diameter, but the nylock took a 10mm socket on an extension and a 1/4 ratchet to work. Oh. And the bolt is mild steel. Rusty as heck. I'm not sure the spacer is necessary as there is adequate material on the clamp to allow it to be enlarged the small amount that the bolt requires. I can pick up a spacer at a local machine shop. I thought about a smaller bolt, but, I forgot to measure it before I stuck it back in.

[windmill]

Another thing they changed, my 2007 Patrol uses a straight pin retained by a cotter pin that fits the retainer as delivered. I recently purchased an old Unimat lathe/mill which I will use to turn down the slave cylinder to fit and make a custom retainer bolt.

[Trumpetwasher]

Another thing they changed, my 2007 Patrol uses a straight pin retained by a cotter pin that fits the retainer as delivered. I recently purchased an old Unimat lathe/mill which I will use to turn down the slave cylinder to fit and make a custom retainer bolt.

Barry, does the parts list show what size that bolt is on a 2016?

[windmill]

Another thing they changed, my 2007 Patrol uses a straight pin retained by a cotter pin that fits the retainer as delivered. I recently purchased an old Unimat lathe/mill which I will use to turn down the slave cylinder to fit and make a custom retainer bolt.

Barry, does the parts list show what size that bolt is on a 2016?

The thread is m6 X 30mm shoulder bolt, but I don't recall the shoulder length. A straight m6 X 30mm cap screw should work with a bushing on the cap end. There are 6mm ID X 8mm OD bushings available but probably not at your local hardware store.

These should work, might need to be trimmed down in length.
https://www.amazon.com/uxcell-Bearings- ... r=1-6&th=1

[Trumpetwasher]

I'm going to try a 6mm cap screw. The hole in the clamp is 6mm. I have some 6x8 bushings. Right now, getting time to do it is the problem.

[windmill]

Turned down the cylinder to 22mm with my newly acquired Unimat. That leaves the wall of the cylinder 1mm thick which should be fine, but the groove for the O-rings is too shallow now and can't be deepened. I figure I'll make a silicone seal in place by putting a couple of layers of masking tape along the groove edges, filling it with silicone sealant, and let it set before putting it in. Since the cylinder is stationary. I think that will be adequate.

IMG_3693.JPG

[Trumpetwasher]

Another speed bump. The ears that the mounting bolt goes through are too thick to allow the clamp to center. I ground a little off of the sides of the clamp, but still need to find a way to take material out of the inside of the cast ears. There isn't much room, without taking the transmission out. Removing the battery won't give enough room. I'm thinking maybe a Dremel tool with a right-angle drive. Ideas?

[jeffsaline]

My suggestion without personal experience is don’t modify the tranie case back. Instead make or modify the clamp. Once you modify the case back it will probably be difficult to return to the stock configuration if you want or need to.

Best,

Jeff

[phughes]

I agree with Jeff. With guns we always say, modify the part, not the gun. Why destroy an expensive case to fit a $60 accessory?

[Trumpetwasher]

The area where I need too remove a very small amount of material won't prevent using the original release. There appear to be casting marks, parallel lines on the inside of the casting "ears" about a millimeter above the bottom edge that prevent the cage that holds the captive 8mm Nylock nut from clearing. It would be similar to removing powder coat. Anyway, it requires a 90° Dremel attachment in order to have work room. Coming Sunday.

[windmill]

I hit the same issue.... no problem....grind .5mm off each side plate with my Unimat. But now...... because I reduced the diameter of the slave cylinder the retainer is too short.....

Looks like I'll need to make a new retainer from scratch. Think I'll do a simplified one-piece unit.