1974 XS/TX650 rebuild

[th62]

More on the hydraulic clutch conversion. A total fup!

This is a new 20mm clutch slave cylinder I machined up for my 74 TX650 to replace the 25mm slave I made. The 25mm slave didn't work as the piston only had around 1mm movement using the 9.5mm master I bought.

The new 20mm slave was machined up from piece of 6061, the piston is 304 stainless and the seal used is from from a hydraulic ram. Instead of using a circlip to retain the seal, I machined a cover to both keep the seal in place and also to act as a dust seal.

To fit the slave I bored out the actuator hole in the clutch cover from 26 to 29mm and drilled the M5 threaded mounting holes out to 6mm and bored them to take allen heads.

The 9.5mm master I bought for it was advertised as using mineral oil, which suited me as I dislike using brake fluid. Unfortunately, the ad was wrong, I used mineral oil and the piston seals swelled up and jammed the piston. WhenI finally managed to get the piston out, one of the seals was damaged, rendering the master useless.

Replacement seals are unavailable for this master, so I decided to retain the screw actuator. This engails returning the clutch cover to original. To do this I turned up a couple of stainless 6mm T nuts and threaded them M5 and pressed them into position. I then turned up a Delrin spacing ring for a press fit around the screw actuator.

It all works as it should now with no obvious signs of the modifications I made. And now I have a 20mm clutch slave sitting in my useless parts bin.

So, all for nought... I'm now back to the original cable actuated clutch.