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I tried it on my 98 Ev and the 2001. never satisfied hard to bleed and worked great until the engine heat built up then the free play changes. I finally sold it to somebody that knew the deal but wanted it anyway.
If the clutch fluid lines were run too close to something hot and DOT3 was used, could the fluid have overheated?
This is spendy but oh so easy to add:lhttp://www.mgcycle.com/index.php?main_page=product_info&cPath=193&products_id=2554
Yes, and as I said, a hydraulic system should self-adjust each time the lever is released anyway.
Wouldn't an expanding shaft decrease freeplay?
Within limits. At some point, insufficient piston travel exists to do the job
If the piston travel in the disengage (pressure) direction were too short, the piston would hit the end of the cylinder and the lever would bind before being able to release the clutch. Alternatively, if the cylinder were open-ended, the seal would come out the end and leak fluid badly. If the travel were too short in the retract direction, the piston would hit the other end of the cylinder before releasing pressure on the clutch and the clutch would probably slip. Also, the master cylinder lever would continue to its "home" position and draw fluid in as usual, so next time it was squeezed, it would move the piston without excessive play. This means I don't think insufficient piston travel was the cause of excessive play. Rodekyll's theory of boiling fluid is still a possibility, but only if the hose had been routed in a way that got it hot enough.