Saturday, February 9, 2019

Clutch, primary master link

Readers will be aware of the chain master link issue previously mentioned in older posts. I discovered exactly the same problem with another split pin cotter subsequently missing. It was discovered in 3 pieces in the bottom of the primary case. The symptom was the same, the tails of the cotter were broken as if by fatigue. After studying and reflecting on the issue, I've decided to use 1.6mm welding wire. This is some left over from TIG welding chromoly. It feels tougher than mild wire. I'll insert a pre-cut length then bend the tails in the form of a "Z" pattern. Minimum length tails cut short to reduce fatigue..
Update: I elected to use regular mild steel wire after I discovered the tougher wire broke too easily when bent and forth. I plan to inspect after some miles.
Pic: master link with 1.6mm wire inserted and ready for the 2nd bend and snip to length..




The clutch pressure plate has worn the area where the release bearing fits. There'd be 1mm (.040") or more wear. The plan is to braze the area and lathe a new seat for the bearing making it a light tap fit.
I'll make a plate to keep it from warping. The same plate will be used to mount it to the face plate.
Pic of  jig ..


Ready for brazing....

Brazed and turned to size..



A spacer was missing from the release mechanism. It may be the cause of the pressure plate wear. I made it from mild steel. 5/8" bore x 14.3mm long. The outside diameter was made to fit the housing and seal carrier. I plan to harden it.
Pic of spacer before hardening..