ok here we go....
1. that is not correct...the designers did allow for wear on the trow out
bearing and here is what they thought.... their assumption and subsequent
calculations were that the bearing wear would be compensated by a proportional
amount of disc and pressure plate wear. as the disc becomes thinner , the
contact surface of the pressure plate with the bearing would be forced out
towards the bearing by virtue of the prings in the pressure plate. think about
that for a minute ... as the disc wears the pressure plate moves closer to the
flywheel and so moves the throw bearing surface further away from the
flywheel.whether or not that makes sense to you and me is irrelevent.. that
was the logic of the BMC engineer staff at the time.
the above is not so hard to believe when you consider that there is no adj.
for front end specs....if they are out of aligment, you replace the "worn or
damaged parts". you are not given adj. points. same "replace worn or damaged
parts" idea for the clutch.
2. yes you probably did bend the fork, and/or caused excessive wear in the
fork pivot bearing to cause looseness.
3. if you asked me that question in 1962 when i was working as a mechanic for
a BMC dealer i would have been able to tell exactly how long to make the rod,
but i have since forgotten.
with the above in mind...picture this....
your fork is now bent or worn for whatever reason, you happen to install a
disc that is unusually thick and a pressure plate that has been adj. at the
end of its tolerance so that the trow bearing area is as far away from the
bearing as is "legally" possible. add a couple of worn parts and bushing here
and there the system and there you are ......no clutch.
remember bmc says everything must in working order if not replace it.
i have used these basics premises for decades now and i have never been
dissapointed in finding the reason why a clutch has failed to work or to get
one working for me.
if anyone has questions about a specific clutch problem i"ll be happy to help.
as long as i am given the facts i can resolve the problem and exactly pin
point the culprit in most cases, in the remaining 10% i'm just happy that the
clutch is back working again.
thanks for reading