Clutch pushrod doesn't fit back in.

[Scartman]

Hi all, just finished putting engine back in the frame on my K2. Refitting the clutch slave cylinder and for some reason there's about an inch gap. I know the pushrod didn't grow in length, I do think the clutch lever was depressed when the slave cylinder was detached. Any thoughts, advice welcome

[Hooli]

If you can't push the clutch slave piston back by hand, it'll be stiff but should move. Then open the bleed nipple so the slave goes back, it's the easiest thing in the world to bleed so no great hardship & these bikes do cook the fluid down there quite quickly.

TBH I'd strip & clean the clutch slave anyway. They get a build up of crud that jams them up over time.

[seth]

Nice 1st post 
As hooli says check and clean the slave cylinder .
As you say the motor has been out have you had the actual clutch apart and is that back together properly?

[grog]

Welcome Mate, intro would be welcome. Lets hope slave just needs re seating. Why was motor out?

[Scartman]

Hi again, by way of a belated intro....
Had my K2 (Doris) since 2014, I bought her as a standard, no mods, low mileage bike when I lived down south. I moved back to the midlands, Derbyshire, a few years back and have ridden her most days commuting as well as camping holidays and weekends away. She's getting a bit tired now so I decided to do some updates. New brake and clutch hoses, refurbed the brake caliper's master cylinders and the fork oil and seals etc, and decided on a new exhaust (the original downpipes had rotted at the clamps to the collector box, it passed MOT but started blowing not long after). Whilst fitting the new Delkavic exhaust, a simple job I thought, a bolt sheared off in the head in the most awkward place it could. So I whipped the motor out to sort out what I thought was a straightforward extraction and thought I'd renew some old nuts and bolts whilst I had the chance. Soon found out it wasn't so straightforward, but that's another story. Anyway, put the motor back in and came across the problem of the clutch pushrod not seating correctly. Stripped the slave cylinder and can't get the piston to move in or out. Going to try the compressed air method as it worked when I did the brake caliper refurbs but my compressor is dead so it will be a trip to the local garage. I've ordered a new seal kit, which should be here this week. What I can't quite get me head around is why the slave cylinder won't go back on? I've taken the housing off loads of times to de-gunge it (not removed the hose). Clutch fluid was replaced when I replaced the hoses and master cylinder refurb and that was only 2 months ago. Clutch was sound before I took the motor out. Just over 37,000 on the clock so I'm not quite ready for a new clutch yet.     

[Hooli]

37k isn't even run in for one of these!

Doesn't make sense why your piston won't go back, there's a spring behind it but it's not very heavy & can be pushed back easy enough.

To ask a stupid question, you have taken the cover off the slave? the one held with two crosshead screws & a hole for the pushrod. The piston is behind that.

I'm not far away so could take a look in a week or so if you've had no luck. I know my way around these bikes reasonably well these days.

[Irish in Oz]

I hope you don't have a problem similar to this.

[Kiwifruit]

Thriving on neglect Irish 

[Irish in Oz]

Exactly, this bike was used everyday all year round, now it's only used occasionally so this is what happens.

[grog]

New parts required Irish. Spray new bits with Lanox, use gear oil instead of spray lube. Will stay much cleaner.IMO.

[Irish in Oz]

@grog Complete new cylinder and piston ordered from Suzuki.

[Scartman]

Not quite as bad as that it turns out....
After looking at your photos I realised that the piston wasn't sat level in the cylinder, so I put it in my wood vice and slowly squeezed the piston back into the cylinder. It went with a pop and sat back into the cylinder with no drama. I could then push it by hand as far as it would go and could then see some corrosion around the top of the cylinder.
I cleaned this off with some metal polish and the piston fell out.
Polished the cylinder, renewed the seal and spring and the dilemma has been resolved. Slave cylinder back on the bike and now it's on with the rebuild.
Thanks to all who replied. This forum is fantastic and far better than just a workshop manual.
Thanks again, no doubt I'll be back on here soon enough before I've finished.

[Kiwifruit]

That'll be $29.95 + sundries & disbursements +vat +gst.
or you can put your card on the virtual bar   

[Scartman]

Cheques in the post....