UL clutch release lever catching on top of primary case

[Martin Pettingell]

I'd welcome some help on this issue.

I have recently restored a 47 UL. When i first had the bike the clutch release lever was not only hitting the top of the primary chain case but had also been allowed to come into contact with gear box top lid and the rear drive chain that had been running out of adjustment. It was an original lever but had clearly seen better days and had worn very loose on the release lever stud over the years causing it to drop.

The gearbox has since been totally rebuilt with a new stud and lever. The primary chain cases (both inner and outer) look like old aftermarket parts.

The bike is back together and on the road and i'm ironing out a few problems. Mostly matters of adjusment.

One problem is that the clutch release lever is still striking the primary chain case on the very top of the lug that houses the inner/outer primary connecting screw.

The problem is nowhere near as bad as before (just a few mm's) but any contact between those two parts needs dealing with. It has already knocked the paint off the top of the case and is starting to wear a little groove in the lever.

I am not sure what is causing this. I have considered that it might be the primary cases being aftermarket could be slightly larger than the original. Or maybe the lever itself is not set at the right angle. Should i try another lever (on try and adjust/bend the one i have)?

The stud has some play in it in so far as it can be lifted vertically a few millemetres in its bushing - which raises the lever comforably above the primary case - but of course it wont stay in that position. I wondered if the stud was too short?

I have studied all the photos and other literature i have and it seems that there is a good deal of variation in the distance between the end of the lever and the top of the primary case. Some clear it with room to spare others look like its a bit tighter but i cannot find any reference to the problem i am having (i have searched this forum and drawn a blank - so sorry if i have missed it somewhere).

I will have to tear down the back end of the bike to access the lever but before doing so i'd like to indentify the problem rather than just trying to fix the symptoms.

The clutch / gearbox / primary set up was one of some long standing over a range of models so i am thinking that i am just missing something obvious here but cant figure it out

Thanks in advance

Martin

[shelbyinparadise]

I might be able to help, as I have run across this before. Under the clutch release finger is a washer 6443HW in newer parts book having a size of 13/32 x 11/16 x 1/16. I remember the early washer being a little thicker than a plain washer, and since the clutch release finger sits on top of this washer it raises the shaft and clutch release lever up higher. If you have up and down play between the clutch release finger and washer larger than about .010 - .015 inside kicker cover you need a thicker washer to take up the slack from wear or? The late models, later than 1965, used a different length and shape arm and it sitting a little low with plain washer was not a problem. I am thinking you are adjusting the clutch to have the correct amount of travel from the rear most position of lever since you are not hitting the top anymore in the forward position of lever.

I can only speak of how oem parts fit, if using aftermarket shaft the flats might be longer allowing the lever to sit lower?

Hope this helps, Shelby

[Martin Pettingell]

Shelby,

Thanks - that sounds like the problem i have and maybe the fix. I will take off the kicker cover and take a look at the washer and see if a thcker one does the trick

The lever does not seem to be contacting the top of the box any more and the clutch works just fine as currently adjusted.

I just need to raise the lever a tad and a thicker washer may be just what is required

Appreciate the reply

Martin