It took a while but here is the update I said I would post.

First of a correction: my first test of a new bell crank mentioned above was not a 15mm diameter - but 20mm. As mentioned, this was touching the gearbox. Rod diameters up to 16mm will work. This is what I finally ended up with.

When you are testing your bell crank - get a digital angle meter. When you press down the clutch pedal, both levers should change their angle the same amount. This helped me to track down the main issue - material fatigue and torsion force on the bell crank. If the lever that the clutch cable attaches to does not do this - you know that the material of the crank cannot cope with the torsion force anymore. This is turn leads to limited travel of the clutch cable.

Maybe I am wrong, but I came to the conclusion that the CVH clutch setup is with a constant-contact release bearing. This explains the description of the Gomog article as well as the fact that lever the release bearing is attached to, does not have a return spring or similar.

I changed my setup slightly by adding a spring and extending the cable travel to an intermittent setup. Both setups will work, but make sure your bell crank is strong enough. Otherwise you might make the same adjustment mistake that I did: pulling the release bearing onto the pressure plate to tightly, just to be able to get the gears in.

When you replace the clutch cable and the new one is slightly shorter: don't panic. Just get a new guide sleeve on the gearbox housing. In order to rule out material fatigue of the cable itself, I got a new cable from Brands Hatch Morgan. The inner cable was about 2cm shorter. The length of the thicker part of the guide sleeve (which is going into the bell housing) determines how much the inner cable will stick out from the cable mount close to the lever of the bell crank.

A longer article about the topic including drawings for a new LHD Bell crank can be found on my blog

I hope that helps others when they look into adjusting the Morgan CVH cable clutch.

Regards
Tim

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