Pushrod and ball

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Mar 14, 2012
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Hello,
I broke three fingers on my left hand a year ago, since then I can't bend them completely and of course it's very, very annoying for the clutch lever of the commando.
I would like to cut the pushrod and put a ball in the middle.
How do I cut where to cut the rod and it is the existing ball that I have to put in the middle or an other ? https://andover-norton.co.uk/.../bearing-ball-chrome-1-2...
Is there an Australian company that has designed something like this?
Thanks for your help.
 
I would like to cut the pushrod and put a ball in the middle.

You'd be better off adjusting the stack height if your idea is to lighten the clutch pull.

How do I cut where to cut the rod and it is the existing ball that I have to put in the middle or an other ? https://andover-norton.co.uk/.../bearing-ball-chrome-1-2...

The existing lifter mechanism ball is 1/2" (12.7mm) diameter...
" 04.0031 BEARING BALL CHROME 1/2" (12.7mm)" so is far too large to fit inside the mainshaft."

The pushrod is 6mm diameter so you need a 6mm ball bearing. You'd need to harden and temper the cut ends of the pushrod or they are likely to wear quickly.
 
RGM sells two clutch plates to adjust stack height, 3mm (2.8mm measured) and a 4mm (3.8mm) thickness. Stock on my 850 were 2mm. I measured force need on clutch lever to pull it to bar using a luggage scale and found 22 lbs stock, 16 lbs with one stock plate replaced by the 2.8mm plate, and 11 lbs is the 3.8 mm plated was swapped. I tried test riding with 3.8mm plate and all was great until I tried a sudden throttle twist to nearly full while in 4th and going 60mph on flat road... this caused a brief clutch slip. Could have kept that nice light lever pull and just avoided sudden torque demands, but went to the 2.8mm plate and no more slip can be made to happen. Lighter pull has helped with my hand fatigue and tendenitis.
 
I went to a rally last year and a new friend said the best thing he did was buy / fit a hydraulic clutch . So... who sells this ?
 
Hello,
I broke three fingers on my left hand a year ago, since then I can't bend them completely and of course it's very, very annoying for the clutch lever of the commando.
I would like to cut the pushrod and put a ball in the middle.
How do I cut where to cut the rod and it is the existing ball that I have to put in the middle or an other ? https://andover-norton.co.uk/.../bearing-ball-chrome-1-2...
Is there an Australian company that has designed something like this?
Thanks for your help.
Also... as far as I know the ball in the middle of the pushrod doesn't make clutch operation lighter, it is just a partially effective way of stopping oil migrating from the gearbox into the primary.
I have a cNw hydraulic clutch and is is truly great - can thoroughly recommend it.
Cheers
 
Also... as far as I know the ball in the middle of the pushrod doesn't make clutch operation lighter, it is just a partially effective way of stopping oil migrating from the gearbox into the primary.
I have a cNw hydraulic clutch and is is truly great - can thoroughly recommend it.
Cheers
A hydraulic clutch should be smoother but will not necessarily give greater mechanical advantage than stock if stack hieght is off.
 
Years ago I brought 2 thicker alloy pressure plates (1 as spare...dont recall the measurement) to increase the stack height...with a nice new routed cable and a inner clutch hub in good condition you can have a 1.5 finger clutch operation with out slippage
As good almost as a well set up hydraulic clutch that I now use for the Commando 👍
 
@fiatfan if you do go hydraulic, make sure you use Dot 5 fluid (silicone) as it does not absorb moisture and (I have spoken to supplier tech lines) does not have a recommended change-out date. Other brake fluids, Dot 3, Dot 4 & Dot 5.1, are glycol based and absorb moisture so need replacement regularly.
PS: Matt fills his brakes & clutches with Dot 5
 
A hydraulic clutch should be smoother but will not necessarily give greater mechanical advantage than stock if stack hieght is off.
other than avoiding the inevitable decay of the inner cable lining leading to more friction and... grunt!!
Stack height is of paramount importance also.
 
I wonder if putting the 750's pressure disc which is 1/4 instead of the 850's 1/8 would be equivalent to putting a smooth disc in addition which should maybe make a softer clutch lever?
What do you think about it ? Will the large clip fit in the groove ?
 
I wonder if putting the 750's pressure disc which is 1/4 instead of the 850's 1/8 would be equivalent to putting a smooth disc in addition which should maybe make a softer clutch lever? What do you think about it ?

+ 1/8" (3.175mm) would likely be far too much. +1.0mm is probably safe but any more could potentially cause clutch slip.

Will the large clip fit in the groove ?

Probably not without the spring going 'convex'.
 
I fit the RGM 4mm (3.8mm measured) plate in place of one original 2mm plate on my 850 and that gave clutch slip at high torque demand. That's 1.8mm added. So adding 3+ would be pretty extreme and insuring a very slippy clutch.
 
@fiatfan if you do go hydraulic, make sure you use Dot 5 fluid (silicone) as it does not absorb moisture and (I have spoken to supplier tech lines) does not have a recommended change-out date. Other brake fluids, Dot 3, Dot 4 & Dot 5.1, are glycol based and absorb moisture so need replacement regularly.
PS: Matt fills his brakes & clutches with Dot 5
There have been reports of DOT5 causing certain issues. One problem is it can aerate/foam from vibration and b/c of this is not recommended in ABS braking systems. Also, if converting from Glycol fluids, any residual moisture within must be removed b/c it will not mix with DOT5, and forms a layer at low points in the system, leading to corrosion etc. Good things about DOT5 are no moisture absorption from the air, high boiling point and no paint damage effects.
 
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