Michael if the pedal is not hitting the floor I would suspect the slave cylinder circlip as Simon says.
This thing really has no function once the cylinder is installed, I'd pop it out and try again.
As flywheels get lapped onto cranks,clutch arms wear, thrust washers get changed, etc etc the whole flywheel assembly gets closer to the block and the slave runs out of travel.
There are other ways to rectify this but removing the circlip is quick and easy, with no detriment.

_________________
DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

dunno - depends how much the little amount off the posts equates to at the end of the arm

it only takes 5 seconds to flip the boot off the slave and get your missus to put her foot on the clutch

The last 2 clutch assys I've done for people needed around .070" off the posts. This is due to facing of flywheel and backplate surfaces over the years.
Sounds normal to me.

_________________
DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

Thanks Kev. I hope it is as easy as that

how much travel do you gain from ditching the circlip and how much before it pops out (well ok it is more likely to leak fluid past the circlip groove, but you know what I mean)?

cheers
michael

_________________
the world is a book, and those who do not travel read only a page
66 Mini Minor sponsored by http://www.lifeonthehedge.com.au/ The Dog Harness Specialists
It was a pleasure ausmini. I'll miss all you misfits and reprobates

Ive been through all this and had the posts machined to get the diaphram flat. All working well now - however the root of my clutch problem was a bent clutch arm . This prevented the clutch disengaging properly and was ugly! It was hard to tell , but the very tip of the arm (at plunger end) was bent which made a huge difference at the other end. Before you do anything else , check the arm against another. Try an old one or get a new one.

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Now with 2 extra ports!

Every time I do a clutch job, I have to think. Yep, as per the manual, the hub/boss faces away from the flywheel/towards the engine.

Signs of dementia

Every time I do a clutch job, I have to check. The hub/boss faces away from the flywheel/towards the engine.

Signs of dementia

Its Marcel Chichak by the way, that wrote that excellent article.

If it turns out to be the circlip in the slave cylinder, you can add 1/2" or so to the plunger arm, to push the piston back in the slave cylinder.

_________________
Steve

oops, got the name wrong. it was late last night when i wrote it.

Can you just get a longer rod off another application?

Maybe an adjustable rod is a good idea?

thinking too far ahead there, need to measure tonight.

cheers
michael

_________________
the world is a book, and those who do not travel read only a page
66 Mini Minor sponsored by http://www.lifeonthehedge.com.au/ The Dog Harness Specialists
It was a pleasure ausmini. I'll miss all you misfits and reprobates

An easier way if the wok is off- put a flat washer behind the release bearing.

_________________
DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

between the shoulder of the plunger and the bearing?

_________________
the world is a book, and those who do not travel read only a page
66 Mini Minor sponsored by http://www.lifeonthehedge.com.au/ The Dog Harness Specialists
It was a pleasure ausmini. I'll miss all you misfits and reprobates

yes. This pushes the whole lot back including the clutch arm and the slave pushrod.

_________________
DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

yep, just need to work out how thick, assuming that this is the actual problem.

_________________
the world is a book, and those who do not travel read only a page
66 Mini Minor sponsored by http://www.lifeonthehedge.com.au/ The Dog Harness Specialists
It was a pleasure ausmini. I'll miss all you misfits and reprobates

take the pin out of the clutch arm to the slave cylinder. push the slave right back until it bottoms out and then pull the clutch arm until it pushes the thrust onto the pressure plate. measure the distance between the hole in the slave rod and the hole in the clutch arm. that's how much "loss" of movement you have. You might have to make up a extension piece and weld to the end of the slave rod . IE like adjustable rod.
I usually make a new rod to suit after I have machined the crap off flywheels and back plates.

_________________
Research is the difference between speculation and investment. Anyone who copys some one else will always be second
www.minisprintgt.com

always good to hear your input Dave.

Sounds like this might be the best solution, pending measurements tonight.

Thanks

_________________
the world is a book, and those who do not travel read only a page
66 Mini Minor sponsored by http://www.lifeonthehedge.com.au/ The Dog Harness Specialists
It was a pleasure ausmini. I'll miss all you misfits and reprobates