Lever plunger ?

[Panman40]

So after swapping my levers over I managed to mess up the tiny 2mm Allen grub screws you have to loosen ( covered in red threadlock) , I thought each part could be purchased separately having read another forum but the dealer said unlikely as it looks like that plunger rod is part of the master cylinder at £385!!.
Anyone know different ?.

[Stu]

What do you mean you have messed it up?

[Panman40]

What do you mean you have messed it up?

Rounded out the 2mm Allen grub screws as they were very tight with loctite on the brake side, the clutch side was fine. It’s usable but I’d rather replace it.

[David.]

Remove the clutch side, check the size and see if Stig Fasteners have one to fit, https://a2stainless.co.uk/page/1/?s=gru ... pe=product

I've read that they may by M4 x 8mm x 0.7mm pitch.

[Stu]

Remove the clutch side, check the size and see if Stig Fasteners have one to fit, https://a2stainless.co.uk/page/1/?s=gru ... pe=product

I've read that they may by M4 x 8mm x 0.7mm pitch.

I believe its all part of the plunger so you can't just replace the grub screw

[Stu]

Rounded out the 2mm Allen grub screws as they were very tight with loctite on the brake side, the clutch side was fine. It’s usable but I’d rather replace it.

That makes sense! I would maybe scour ebay and see if you can get a replacement because as you say you can't just replace the plunger

[David.]

Is it the plunger adjuster or grub screw in the barrel which is rounded out.

Plunger.JPG (16.04 KiB) Viewed 2323 times

If it's the grub screw, this might do the trick, https://a2stainless.co.uk/product/m4-x- ... in-914-a2/

[David.]

I managed to mess up the tiny 2mm Allen grub screws you have to loosen.

Is this the grub screw in question which needs to be loosened to adjust or remove the plunger.

2mm Allen.JPG (44.27 KiB) Viewed 2314 times

Adjusting the plunger.

Adjusting Plunger.JPG (34.86 KiB) Viewed 2311 times

[Panman40]

Is it the plunger adjuster or grub screw in the barrel which is rounded out.

Plunger.JPG

If it's the grub screw, this might do the trick, https://a2stainless.co.uk/product/m4-x- ... in-914-a2/

Both!, are you thinking drill them out and try and re tap the threads ?.

[Panman40]

I believe its all part of the plunger so you can't just replace the grub screw

Ahh yes your correct, I did adjust it using pliers but marked it up a little, I’m getting careless in my old age

[David.]

Were the grub screws removed from both the brake and clutch levers, with the plungers being removed and reused in the replacement levers.

[Panman40]

Were the grub screws removed from both the brake and clutch levers, with the plungers being removed and reused in the replacement levers.

Yes, but I couldn’t remove the locking ones, I should of left it at a half turn really it’s a very strange setup to be honest.

[David.]

I'm confused (easily done), were the plungers removed without removing the grub screws, then screwed back in.

[Panman40]

I'm confused (easily done), were the plungers removed without removing the grub screws, then screwed back in.

Yes, when I went to tighten the brake grub screw after threading in the plunger it was stuck fast and rounded out the hex. As it happened the thread on the plunger was a little burred so locked off tight when threaded back in.

[David.]

Could the thread on the plunger be dressed up using a die. The grub screw in the barrel could be drilled out and threads re-tapped, together with the thread for the plunger. Or, drill out both threads and fit Time-Serts to repair the threads. Alternatively, have a new barrel manufactured.