Clutch lever spring

I am not saying that it can't be done but unless you are medically qualified in keyhole surgery it is probably easier to drain the gearbox oil and take off the outer cover. Also, there is the potential to lose the giant circlip into the box and the ball bearings not to mention broken bits of spring.

If someone has done it without removing the cover I am sure they will let us know.

Good luck,

Dennis

Find a way to lean the bike over. On your lawn with a box and an old mattress - or some such arrangement. No need to drain the oil then, when removing the cover.

It seems to me that John is referring to an arm with a ball bearing.

And Dennis is referring to a giant circlip and ball bearings.

So I don't know if we are talking about the pre-1964 gearbox or the 1964-on gearbox.

It would be very helpful if the original question stated early or late gearbox. The early gearbox has a lever, returned by a coil spring, pushing a single ball bearing in the direction of the clutch pushrod.

The later gearbox has a pair of plates, one fixed and one (with lever) rotating. Three ball bearings between the plates and the assembly held into the gearbox by a giant circlip.

I agree with Dennis that there is nothing to be gained by surgery through the oil filler hole. Do the job properly and see what you are doing and what's gone wrong. And find any broken spring bits.

All fixed now John?

Peter

John,

I was hoping someone with recent experience would come up with the advice. Maybe you have done it now.

On this website, under the heading Technical, is a splendid Light Twins Compendium v 2.1.

On page 26 is a good exploded diagram of the early lightweight gearbox. Andy Sochanik, on pages 26/27 describes how to remove the gearbox cover and the clutch actuator lever. The spring is fitted over the barrel of the lever. Hook to arm of lever. Then the castellated nut, clutch operating body, ball, etc. assembly is the reverse of disassembly. Take great care to check  item 72 clutch operator body peg is in place and engaged in slot on operator body.

A common fault is item 70, locking ring, 041702, loosens in operation and the clutch lever pushes the clutch operating body backwards, rather than driving clutch pushrod forwards. Clutch does not disengage fully.

If your locking ring has damaged threads or fails to seat properly and securely, you are heading into future problems. The locking ring needs to be tight.
Ride safe

Peter