Clutch lift

The movement you haveon yourlaydown box seems pretty much par for the course, Charles. I've never seen an official figure but Iwas similarly surprised whilst going through an unsuccessful attempt to fit an RGM Belt Drive Kit to a 1956 Dommie 99 with a laydown box.Originally mine was about 40 thou also with 7/8" pivot levers. Trying every tweak possible and using 1.125" pivots the maximum increased to 0.062" as shown below, still not enough to operate the diaphragm clutch to the standard one would wish. By comparison I found the AMC clutch mechanism givesmore than double that throwwith the same levers.

Oh dear,another double posting ! Please someone, whencan we have a more user friendly forum formatting system for editing messages and attachments !

It's almost impossible to operate the Commando diaphragm clutch using the slow worm on the laydown boxes. The best option is an unequal whiffle tree pivoting under the fuel tank.

I believe that such a conversion is available for current Royal Enfields but I can't find a link.

wondered if this would help in some way. you will find it about a third of the way down the page that loads up . Baz

https://penforhire.wordpress.com/2007/08/19/it-lives/549/

Hi Pete, I too am plagued by not enough clutch lift on my lay down box. I have managed to attain almost a 1/16" by filing the edge of the handle bar lever blade back almost to the cable nipple, which allows a longer arc for it to pull out the cable. Also, I have drawn up on paper the full size diagram of the actuating worm lever inside the gear box. I then drew it up with a shortened lever (by about 1/8")and found this would give maximum movement of the worm screw, and increase the lift (sacrificing only a little bit of lightness on the handle bar lever pull) This can be easily achieved by cutting (on a long angle)and shutting the worm actuating lever. Brazing it back together afterwards. I will try this one day!

Paul.

I did consider shortening he worm actuating lever as you suggest Paul but shied away from the risk of butchering a perfectly serviceable component. Inspired by a photo that Richard had posted of a beautifully engineered "unequal whiffle tree pivoting under the fuel tank"I adapted the idea to a cruder version of my own as shown below. This finally gave all the throw needed for a laydown box to actuate a diaphragm clutch unit but the increase in lever pressure, whilst still manageable, did not seem a worthwhile trade offjust to have an oil free primary case, so I reverted to the original setup.