OK it is the slave cylinder circlip stopping the travel.

I like the idea of the longer rod from Dave so that is where I am going to go with this one.

cheers
michael

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the world is a book, and those who do not travel read only a page
66 Mini Minor sponsored by http://www.lifeonthehedge.com.au/ The Dog Harness Specialists
It was a pleasure ausmini. I'll miss all you misfits and reprobates

Easy fix then

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Mike I'v had the circlip out for a long time now and its the wifes daily drive give it a go before looking for a longer rod unless you have 1

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Stop Licking the Dog...I Don't Care Who Started It

I have the circlip out and have full pedal travel but still no disengagement.

Off to Poland for the weekend so I have no time to investigate.

_________________
the world is a book, and those who do not travel read only a page
66 Mini Minor sponsored by http://www.lifeonthehedge.com.au/ The Dog Harness Specialists
It was a pleasure ausmini. I'll miss all you misfits and reprobates

Try another clutch arm ,preferably New one.

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Now with 2 extra ports!

it is new clutch arm, new plunger, well lubricated, so there is no wear there

_________________
the world is a book, and those who do not travel read only a page
66 Mini Minor sponsored by http://www.lifeonthehedge.com.au/ The Dog Harness Specialists
It was a pleasure ausmini. I'll miss all you misfits and reprobates

If the arm geometry is out, which it seems to be (since you've had to take the circlip out of the slave), might need a washer behind the thrust bearing as the Doc has suggested. This will help restore the working radius of the ball on the arm, that sits in the plunger.

Also be sure the the M/C is 0.70" Bore and it doesn't have that shim under it.

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Clutch MC should be 0.75" (as some were), the .70" ones barely moved enough fluid for the clutch to work at all.
I had a 0.70" one once, the only fix that let it work was to make the MC pushrod longer to get more pedal stroke. But it felt weird having the pedal higher. I fitted a 0.75" one and never looked back.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

Yes, this is correct (trying to do 3 things at once!)

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yep it needs a washer under the bearing. it was running out of ball movement.

I reckon this was the root cause of the problems.

Only trouble I have now is that I can't extract the bearing from the plunger I have managed to destroy the bearing, but guess what the only spare part I don't have here is?

i changed the slave seal because it was weeping, but I think once I have the washer under the bearing all will be good.

cheers
michael

_________________
the world is a book, and those who do not travel read only a page
66 Mini Minor sponsored by http://www.lifeonthehedge.com.au/ The Dog Harness Specialists
It was a pleasure ausmini. I'll miss all you misfits and reprobates

You can use a 5203ZZ, nearly every bearing shop will have them, they are cheaper than the stock item and they are way better than even the old flat faced one (they are a double row angular thrust bearing). You might have to grind a little out of the thrust plate on the diaphram and it is a 'floater' on the plunger. I have never worried about pinning them and never had a problem, but if it does bother you you can always shim it.

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.100" washer and a new bearing all is well again.

It is well after midnight now (goddam too thick engine mounts ) so I can't do an engine running test, but I checked it by sticking in gear and rolling the car with my foot on the clutch. Seems ok by that method.

Also checked the adjustment by looking at the movement imparted on the dial indicator and then ensuring that I got my thrust clearance back by levering the crank damper back again. This was to make sure that I am not running the bearing up against the thrust plate to gain enough travel to disengage, which will destroy the crank thrust bearings again.

I have a farewell party after work tomorrow so I can't test until late again ... I might be tipsy enough to not care about the noise then

Thanks again for the advice guys.

cheers
michael

_________________
the world is a book, and those who do not travel read only a page
66 Mini Minor sponsored by http://www.lifeonthehedge.com.au/ The Dog Harness Specialists
It was a pleasure ausmini. I'll miss all you misfits and reprobates

managed to start it up and test tonight briefly. Clutch is the best I can remember for this motor.

At least I know all the pitfalls and intimate details of the necessary adjustments.

Hopefully get it out for one more big run before we leave

cheers
michael

_________________
the world is a book, and those who do not travel read only a page
66 Mini Minor sponsored by http://www.lifeonthehedge.com.au/ The Dog Harness Specialists
It was a pleasure ausmini. I'll miss all you misfits and reprobates