My clutch went south while riding north

[ssevy]

On my return trip from the Triumph Rally in Oley PA a few weeks ago, I noticed that it became more and more difficult to shift as the day progressed. Eventually I had no clutch at all, so I never speed shifted down any lower than 3rd gear, and rerouted to avoid stop signs on the last leg home.
I finally got time to pull things apart today, only to discover that the clutch fluid was nearly dry in the master cylinder. I drained and removed the slave cylinder, and it was a mess inside. Brake fluid had passed around the seal and leaked slowly out, and when I pulled out the piston the cylinder had a band of red sediment stuck around its circumference.
I used some brake cleaner and fine steel wool to clean up the slave cylinder, and then installed a new piston set, coating the seal with red rubber grease before assembling.
The master cylinder had a torn lever boot, and the insides of it were full of sediment and other nasty stuff. Because of the depth of the snap ring, none of my snap ring pliers would reach, so I filed down the tips of an old set of surgical clamps and used those instead. After a thorough cleaning job, I installed a new piston set in the master cylinder, again lubing the seals with red rubber grease, and then reassembled. I also installed new banjo bolt washers at each end of the line.
Tomorrow morning I will refill the system and expect to have my clutch issues all resolved.
I had rebuilt all of the calipers on my other Triumph last summer, and using the red rubber grease made a huge difference in the braking performance. Normally I replace the fluid ever other year in the brakes, and will now add the clutch to that schedule as well.
I did read through the sticky on rebuilding the master cylinder, but I used a large syringe to suck the fluid out of the slave cylinder first and then opened the banjo bolt so it wasn't a mess. Also, those screws on the reservoir are not Philips, but JIS. If all you have is a Philips, then use a bit and drive it down with a hammer before you turn it so as not to strip these very easily stripped screws. I replaced the regular bleeder with a speedbleeder, and I would encourage anyone doing brake or clutch work to get some red rubber grease, as it makes everything slide together easily, prevents corrosion, and in the case of calipers, makes them return to the open position and not drag. Great stuff!

[nickjtc]

Thanks for the tips. I'm a fan of the red grease myself.

[Sin_Tiger]

  very timely advice, iit's something that gets ignored / forgotten about. I topped up just before Wales and noticed that the fluid was getting closer to soy sauce than is good. I change all those screws to SUS  hex screws as soon as I get it after previous bad experiences, even the new Trophy 

[ssevy]

Just so anyone not familiar with JIS is well informed, the screwdrivers also work just fine on Philips heads, but mot the other way around. My set of three come from Vessel, and they are high quality. JIS bits are also available, but harder to find, at least here in the States.

[nickjtc]

Should I be saying "nyah, nyah" because the clutch on Rhoda is cable operated...??? 

[JayDub]

Should I be saying "nyah, nyah" because the clutch on Rhoda is cable operated...??? 

Nope, you know you shouldn't tempt fate Nick 
The only time I had trouble from a hydraulic clutch was when the nylon line overheated and burst (my bad routing)... but the number of broken/dry/frayed cables I've had....

[Bixxer Bob]

I carry a spare cable. cost me £12 I think 

[Mustang]

Should I be saying "nyah, nyah" because the clutch on Rhoda is cable operated...??? 

until that silly cable end frays ..........................

[nickjtc]

until that silly cable end frays ..........................

Indeed. But that's what a daily pre-trip inspection is for.  :icon_wink:

[JayDub]

I carry a spare cable. cost me £12 I think 

And taped alongside the existing cable so all you have to do is connect each end  innit Bob?

[Bixxer Bob]

It will be next time I get the tank off.....

[Sin_Tiger]

I'm just going to tape £12 to my clutch hose in case of emergencies