G2 clutch pushed length

Information relating to the Matchless G2 or AJS Model 14 250cc Lightweight
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G2 clutch pushed length

Postby Richard Hyatt » Mon Jun 17, 2019 5:08 pm

Hi all,
I've been looking in various manuals but just can't find the correct length of the clutch pushed.
Bike is 1961 G2 if anyone can help please
Thank you

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Re: G2 clutch pushed length

Postby cbranni » Mon Jun 17, 2019 8:14 pm

I found this post by Clanger...........

From what, I've been able to find out, there appear to be two clutch rods:
042208 9.9" long, fitted to G2 or Model 14 up to 1961
042725 10.1" long, fitted to all other models (CS, G5, Model 8, CSR, G2 & Model 14 1962-)

Hopefully the above is correct. Can anyone confirm?



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Re: G2 clutch pushed length

Postby Richard Hyatt » Mon Jun 17, 2019 8:56 pm

Thank you for this , I think my part number is 042208 9.9 "
I'll check mine now

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Re: G2 clutch pushed length

Postby clanger9 » Mon Jun 17, 2019 9:15 pm

In my Lightweight gearbox parts list, I've got the following:
042208 Clutch rod 9 27/32" x 3/16"
042725 Clutch rod 10 3/32" x 3/16"

The "Models" tab in the spreadsheet shows which part is fitted to which model
I don't remember where I got those figures from...
1966 AJS Model 14 250 CSR "cafe racer"
1993 Ducati 750SS

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Re: G2 clutch pushed length

Postby Richard Hyatt » Tue Jun 18, 2019 5:50 am

I should have mentioned , if it makes any difference , it is a single row primary chain and 3 springs.

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Re: G2 clutch pushed length

Postby Martin.S » Tue Jun 18, 2019 7:01 am

It was always a recommended mod for the Triumphs to cut the pushrod in half and insert a ball bearing between the two halves - not worth the effort on the Matchless?

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Re: G2 clutch pushed length

Postby clanger9 » Tue Jun 18, 2019 7:06 am

Richard Hyatt wrote:I should have mentioned , if it makes any difference , it is a single row primary chain and 3 springs.

Then you need the shorter rod (042208). The longer one is for the duplex clutches.
1966 AJS Model 14 250 CSR "cafe racer"
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Re: G2 clutch pushed length

Postby clive » Tue Jun 18, 2019 9:42 am

Martin.S wrote:It was always a recommended mod for the Triumphs to cut the pushrod in half and insert a ball bearing between the two halves - not worth the effort on the Matchless?


The ball bearing would then be running against two ends which have not been hardened resulting in more frequent need for adjustment?
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Re: G2 clutch pushed length

Postby Richard Hyatt » Tue Jun 18, 2019 12:00 pm

thank you all for this

042208 and 9.9 inches

I'm getting some new plates from Russells as well , the springs are the right length so hopefully a decent clutch without the need for mole grips on the lever!!! (which is 7/8" pivot centres)

we've had to wind the springs in so far to start the thing - but looking at them , they are old , hard and glazed so time for new bits.

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Re: G2 clutch pushed length

Postby Martin.S » Wed Jun 19, 2019 2:47 pm

The ball bearing would then be running against two ends which have not been hardened resulting in more frequent need for adjustment?


No No Clive, Pushrods are made from Silversteel - you just heat the ends till cherry red an quench in oil or water. You would also have to subtract the diameter of the ball bearing from the rods length so that the fitted length is the same as before.
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