Tiny bit excited

Pretty sure the clutch is in the right way round BUT now you have me 2nd guessing myself... bit more done today and this is my findings. Happy its not the location of the top hat so went looking at the linkages

1. pedal has limited movement due to its design so in the upper raised position

2. in its lower depressed position - so note I the distance is not that great but is the full length of the movement otherwise would start hitting other bits around it. so happy with the two points above

3. here are the other bits pulled apart and inspected to be ok or reasonable

4. here is the clutch at one extreme location (fully depressed)

5. and again here in its upright position (loads of movement and rotation that i desperately need) my problem is the relationship between the two when connected together. that full range of movement rotation is somewhat lost when connected to the pedal. I have tried numerous times now once connected at the maximum and then minimum length of the connecting rod.

If i can get that range of movement and rotation then for sure the clutch would dis/engage ONCE CONNECTED. that's my dilemma [bigwhistle]

This is what I've posted on an other forum. " How to fine adjust a S1 clutch shaft"
.W.

It's been numerous decades since my experience with Series I's but IMHO it appears that your cross shaft has excessive free rotation. The amount of movement/rotation that you've shown on pictures 4 and 5 of post #981 should not be present when turning the cross shaft by hand/fingers. There should be a small amount of 'free play' until the tophat engages with the pressure plate fingers and then you would need considerably more force to turn the cross shaft further to depress the pressure plate fingers, thereby disengaging the pressure plate from the clutch plate and flywheel. The leverage that the pedal is designed for will achieve this extra force.
I think you need to disengage the splines of the cross shaft and re-engage one or two cogs further round.

I'm not 100% sure about the foregoing but it's probably worth considering.

1. video of tophat and fingers on pressure plate which seems like it should be dis/engaging

pedal feels good and firm, this is me pushing on the pedal with the gearstick out of the way. happy that the top hat is engaging enough to do its thing. But still getting the grinding of the gears - i can only think it might be the clutch plate in the wrong way now, but was sure it was the right way round as it fouls the wrong way in. thoughts please

How much free play have you got at the pedal before you can feel the top hat engaging with the pressure plate fingers?

1. clutch pedal normal location in relation to brake pedal

2. clutch here already engaging with top hat touching the fingers - (again in relation to brake has travelled small amount with lots to go)

3. clutch fully depressed

4. then thought it may not be neutral per se, but seems to be when i played with the gears without motor running of course

5. top hat not touching

6. top hat fully touching, clutch fully depressed

7. video limited movement of cross shaft - needs more rotation i feel

8. video pedal movement - seems fine. PLEASE IGNORE FOOTWEAR

Measure the distance the pedal moves before you feel it touch the fingers. I can't tell accurtely from the photos but it seems to be sitting higher than the brake pedal at rest and a bit lower when touching the fingers - this is the free play and seems a bit excessive.

According to my information the free play should be 3/4".

1. Thanks to all suggestions about to pull my hair out (what's left anyway) trying to sort this out, measured seems like 1inch before touching or firming up though looking through the gearstick hole looks to me as the fingers and the top hat have very little gap (maybe less then 1 inch) however my next finding ....

2. drew a line between the two shaft pieces and a straight line and then clutch depressed

3. Is it just me but looks to me they are not moving together allowing for more slack, could this be the issue. Remember the 186 worked, have replaced with the 202 should not of made a difference IF the clutch is in the right way round everything else should be the same except having rotated the cross shaft, dismantled the bottom fork that has probable changed from the 186 when working.

I don't think its an issue with the gap between the top hat and the fingers.

IIRC the problem with the 186 was overcome/solved when you adjusted the height of the fingers on the pressure plate.
This is why I've been suggesting that the free play is once again your problem. As suggested by JDNSW the free play should be 3/4 inch. An extra 1/4 inch may not seem to be much, but eliminate that and you may be surprised ............. and retain what hair you have left. :ohyes: