Difficult Shifting

[aso215kd]

I'm still working out the bugs in my new (to me) 64 A65.  Last week I changed my handle bars from the USA to the European style.  Replaced the clutch cable with a new one.  Now I have some difficulty with the shifting. 

I checked the clutch adjustment screw and found it adjusted half way through the lock nut.  That didn't look right to me so I took it out and found half of the lock nut threads were stripped.  I looked at the clutch rod and found it to be 11 1/8" long with 1/8" at the end being tapered and with a dimple in the end.  I read somewhere that a dimple in the end was not desirable so I bought a new one.  The new one was only 11" long and the adjustment screw went into the pressure plate so far that the new lock nut couldn't grab any threads. 

I also found the tops of the clutch spring nuts were even with the spring bolts.  I read a bulletin that said the clutch spring screw faces are supposed to be flush with the tops of the spring cups.  I'm starting to think I bought a pig in a poke.

Sorry this is so long, but if anyone can advise me I would appreciate it.

[Cmcl.1959]

Hi,
The best guide I've come across when setting up the clutch has been a series of videos on YouTube on The Classic Bike Channel where Dave Mitchell rebuilds a Lightening (I think).
He shows you how to put the primary side including the clutch together and how to set it up. It's one of the later videos(there are 13 altogether) possibly number 9 or 10.
Look up The Classic Bike Channel everyday bike and scroll through the videos. Lots of other helpful info on things like the gearbox etc. I found it really useful in sorting out the issues I had with my gears.
Hope this helps.
Regards
Clarke

[Allan G]

You've changed the cable and you now have the problem. Don't go changing everything else, get the cable set properly.

[aso215kd]

Thanks for the responses folks.

Yes Alan, you are correct.  I should have known better, there is a difference of 1/4 inch between the one removed and the replacement.  I look forward to putting it back together.

Interesting though, when I took the clutch plates out, I counted six friction and six steel plates.  The Shop Manual and the Parts Manual for the '64 both call for five plates.  Also, the clutch springs are 1/8" longer and spring cups are 1/8" deeper that the "correct by part number" ones that I ordered.  I'm wondering what the previous owner was up to.  Is there a legitimate reason for this setup?
Cheers,
David