When I bought my used ap1 my03 I noticed I had difficult time to adapt to the clutch. At first I tought it was me, new car etc. The previous owner told me he had someone install a ACT clutch kit on the car but install was described as poor. Test driving it was not a big issue but randomly I felt what people here describes as STICKY pedal.

A mechanic told me my problem was the clutch worn out, this didn't make sense to me due the little time and te good engagement the car had. So after a little searching I came up with this 2 things.

https://www.s2ki.com/forums/index.php?showtopic=370792
and
https://www.s2ki.com/forums/index.php?act=S...0#entry11623289

So I went down the car.
and BAM I had this!!!


It was lubed on the shaft but the half sphere was completely dry and for the "scar" damage it was obvious it was not correctly working in the 'cup' space on the fork but on the edge of it!!!

Called the Honda dealer to see if they had this piece... unfortunately it comes with the whole slve cyl assembly for $85.00

My dad who is a veteran McGiver guy (lol) told me if u let me, I will fix this for u.
So after he observed the shaft and attached a magnet to it... he said this is poor iron I can fix this really easy.
We went to a muffler shop and had the scar 'filled'


Got home dad armed himself with these


So he burred out the big chunks with the file. Then he went easy with some sanding paper. Finally he put a drill in a bench vise and attached the shaft to it. he swithched the drill on and he fine sanded down with sand paper.
Final result



Reinstalled with high temp grease.

don't rep me. Rep My dad. He did my day!

 

Whoa! Good job.

 

holy shit loco! your dad is a metal JEDI!!!

 

LOL Indeed! I learned alot from this one.

 

That's pretty badass.

 

nice! just fyi, the slave cyl is not expensive though . and if the ball is that messed up, chances are the slave cylinder will/is going to leak

 

[QUOTE=ikeyballz,Jan 19 2010, 01:20 PM] nice!

 

That is a nice fix!

I noticed my clutch pedal squeaking and finally traced down to the same ball. Mine was not as bad but had worn a point that made noise... two minutes with a demel and some grease and it was quiet and smooth.

 

Don't forget that push rod has 2 ball ends.
The small one going into the slave also needs grease.

The cup in the fork wasn't damaged?

 

no, one side of the cup edge was 'glossy' that's why I presumed it was rubbing on it. but under my finger it felt pretty good, no torn metal or something that could affect again the rod.
The ball end and rod were properly greased using this


info: Saratoga Hi performance grease


edit. I tried to pic the fork's little cup but I failed LOL