One end is like the size of a drill bit.

 

I think the main thing you guys missed was polishing the ball..haha

Mine was pretty shiney when I put it back.
I tried to follow the DIY to a T only thing I did was not use the Urea stuff.

 

Not even going to go there.

 

I only grind the nip down didn't polish. Is it mandatory though?

 

I only grind the nip down didn't polish. Is it mandatory though?
[/quote]

no you won't notice any difference with it polished, nice to do it while it is out of the vehicle but there won't be any downside to not doing it. Even with the nipple it will eventually return and personally I see nothing wrong with even having the nipple in place if you dont grind it down.

 

If you don't polish it, the rough ball will continually grind away iron dust from the fork, and you will be back to a crappy pedal soon.

The nipple will catch on the hole when the pedal is depressed, creating a "click" feeling in the pedal.

Measure twice, cut once

Polish takes 15 seconds.

 

Was leaving the nip a cost cutting measure or there to keep a layer of grease present?

 

I don't believe the slave rod comes with a nip in new condition -correct me if I'm wrong- a but I believe it delelops over time due to the clutch fork having a hole in the cup area where the slave rod ball inserts itself. Over time a nipple develops at the point of the hole as the rod ball wears down. I ground mine down and polished it 2 years ago and put on Honda Hi-temp grease, took it out recently and a new nip was developing. I maybe put on 6000 miles in that time.

 

The tit or nip is a symptom of wear, you certainly want to get rid of it...not that I usually get rid of nips or tits.

 

think of it as a nip and tuck, lol.