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Clutch Operating Lever Issue

Submitted by ronald_wellman on Sat, 25/07/2020
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Commando

See below photo please. (terms used for components are those used the the official Norton Shop Manual) As I can see it there is only one way to position the Clutch Operating Lever so that it can contact the Clutch Operating Ball which then engages with the Clutch Pushrod to operate the clutch.

In section D of the shop manual directly above Fig. D6 it states "....where the clutch the clutch cable can exert a straight pull, as the lockring ...."

1.    I can't even disengage the clutch manually with a pair of locking pliers with the outer        transmission cover removed -- it simply won't budge.

2.   Please look at the photo and tell me what I am doing wrong.

 

 

 

Attachments
ClutchOperatingLever.jpg

Submitted by steve_constable on Sat, 25/07/2020

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Hi Ron

The clutch actuating lever should not be bolted to anything. The holes in the lever serve no purpose. In fact, the new one I bought from Andover Norton had no holes.

See attached pic. The lever part 33, slides into part 34.

The wheel and Bush (36 and 37) then slide into 34 and are bolted in place by nut and bolt 38 and 39. The actuator arm is then free to roll on the wheel and push onto the ball bearing that in turn pushes the clutch pushrod. When attaching the cable make sure that the arm hasn’t dropped down and disengaged from its proper pivot position.

Hope this helps.

 

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4546F8EE-FE87-4362-80FE-7C6C1EC5EDA9.png

Submitted by mikael_ridderstad on Sat, 25/07/2020

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The picture Steve submitted is a bit confusing as it don't show the 1/2 inch ball going in between pushrod and the operating lever. See https://andover-norton.co.uk/en/shop-drawing/516/gearbox

So the lever is hold in place by the ball on one side and the roller on the other side.If you remove the adjust screw on the clutch, you can insert a rod or screwdriver feeling pushrod movement without fighting with the clutch spring. Thus verifying that lever movement transmits to the pushrod. I think I tried as you did with pliers half a century ago. Didn't work, never tried again.

Mike

Submitted by mikael_ridderstad on Sat, 25/07/2020

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And fitted where the roller shall be. Roller shall rotate with bolt as axle. Also important that the clutch operating body is fitted so that the wire pulls in a straight line. Mark inner cover with a felt pen where the clutch cable enters the outer cover.

Thank you Steve, Mikeal and Peter,

Once I realized "the clutch actuating lever isn't bolted to anything" I installed the cable and the clutch now disengages smoothly as expected.

Lesson Learned: Always take photos whenever disassembling anything mechanical.

The referenced video was rejected as "to large" and I could not figure out how to trim it down.

It was just a video showing the pressure plate operating.

Again, thank you for the excellent suggestions that solved my problem.

Ron

 


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