After purchasing aftermarket master and slave cylinders, and bleeding the clutch line thoroughly, I still could not get a clutch release. First I found I put the banjo on the wrong way,..that gave a "little' clutch release but still a no-go. I found that the master cylinder was not getting a full pedal. Which meant the master cytlinder banjo rod was not long enough. So I decided to modify the banjo rod. This is something that anyone can do and it's not expensive at all.
All you need is a hacksaw ( to cut the banjo in half ), a 5/16" die ( to cut threads on each end of the banjo you just cut in half ), two (2) 5/16" nuts and one (1) 5/16" nut extender.
The hardest part is threading the cut ends. You can get almost a 1/2" of adjustment.
Here are some pics halfway through and the end result.
( Didn't remember to get a starting pic, but you get the idea. )

Original Length:

Original Length with Adjuster:

Full Adjustment:

Took me about 1/2 hour to make it..Had a B@#$% of a time getting the two pieces to thread.

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'85 SE - '86 Fastback SE - '99 Chevy K-1500 Z-71 - '00 HD 1200XL Sportster

[This message has been edited by kyote (edited 04-27-2003).]

[This message has been edited by kyote (edited 04-27-2003).]

Guess you didn't know that Rodney Dickman sells an adjustable banjo.

quote Originally posted by California Kid: Guess you didn't know that Rodney Dickman sells an adjustable banjo.

Well, yes,..yes I did. But I didn't want to spend the $20.00 for one of his when I made mine for around $1.00.
I grew up on a farm where we tried to fabricate something first before we went and got the "store-bought" one.
Plus, I needed mine fixed fast,since it's my daily driver, and it's supposed to rain this next week and I don't like riding my motorcycle in the rain.

quote Originally posted by kyote: Well, yes,..yes I did. But I didn't want to spend the $20.00 for one of his when I made mine for around $1.00. I grew up on a farm where we tried to fabricate something first before we went and got the "store-bought" one. .

AMEN! too many peeps these days are simply all about the store bought stuff, rarely do you see the initiative or determination to solve the problem yourself. Good Work!

[This message has been edited by The Aura (edited 04-27-2003).]

Nice job there.

I took a different approach to clutch adjustability. I used a piece of threaded 5/16" bar stock, a couple nuts, and an extended nut to make an adjustable slave cyl pushrod. The construction is pretty similar to your adjustable banjo, with the ends of the rod rounded off to avoid chewing up the slave cyl piston and clutch lever.

[This message has been edited by Blacktree (edited 04-27-2003).]

nice work & good documentation. Glad ya put the tape measure in the pic tho. Not only does it give proportion to the rod, I would've been too confused.

"Wow! That thing strecthes across 3 oceans and 3 continents!"

quote Originally posted by Blacktree: Nice job there. I took a different approach to clutch adjustability. I used a piece of threaded 5/16" bar stock, a couple nuts, and an extended nut to make an adjustable slave cyl pushrod. The construction is pretty similar to your adjustable banjo, with the ends of the rod rounded off to avoid chewing up the slave cyl piston and clutch lever. [This message has been edited by Blacktree (edited 04-27-2003).]

I thought about that too, but in everything that I read, If you do not get a full stroke on the master cylinder piston, you will still not disengage the clutch fully.
Plus the fact that my clutch pedal was not the required 1" higher than the brake pedal , led me to believe the master wasn't getting a full stroke.