Motorcycle Repair: Suzuki Cavalcade 1400, suzuki cavalcade, air bubbles

Question
What is the Banjo Fitting.
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Followup To
Question -
I have a problem with my clutch.  I bled the air out and now I can't get any pressure to build up in the clutch. No matter how many times i pump the clutch i can still squeeze it to the handlebar.  I have the manual and am going by exactly what it says, as far as procedure goes.  I even took a clutch and master cylinder off of another bike that was working fine.  Now I can't get that one to work.  Is their something little that I am not doing right.  I really don't think it is a mechanical thing in the clutch itself becuase I have tried two different ones.
Thanks,
robert.payne@amaisd.org
Answer -
Hi Bob.
 You are right in that it is not a mechanical problem.  It is a proceedural problem that they never mention in the manual.

Here's the part they don't tell you;

Some bikes have an additional problem with both the clutch and front brakes, including my own.  The problem stems from the configuration of the master cylinder, which is that the connection to the hydraulic line at the master cylinder creates a pocket that air bubbles like to hide in (this is
called a reverse trap) and the method for bleeding that section is a little tricky if you've never done this before.

 Here's the proceedure;

1) Bleed the clutch/brake line like normal.

2) Put a wrench on the banjo fitting and squeeze the lever.


3) (NOTE: Use a box end wrench for this) While holding the clutch/brake lever in, crack loose the fitting and reclose it quickly. Have a rag over the fitting connection that you are working on because it will spit at you as pressure expells the air and a little fluid.
IMPORTANT NOTE: Do not release pressure on the lever till the fitting is tightened back up or you will suck air back into the line.

4) Test the clutch/brake again.  If done correctly, you will have pressure near the beginning of the lever movement rather than at the end.

5) repeat as needed, but should not need more than 2-3 times.

Good luck.
FALCON

Answer
Hi Bob.
 The banjo fitting is that connection where the hydraulic line connects to the master cylinder.  There is a bolt holding it on.  That is a specially designed bolt which allows hydraulic fluid to flow through it into the lines and back to the master cylinder.

Good luck.
FALCON