I'm getting a bit stressed about whether I will have enough "throw" in the clutch actuating lever. I replaced the clutch and all looked well except that the bearing wasn't designed for the release forks on my car. I had to use the original but it looks like I won't be able to achieve enough leverage before I run out of thread on the clutch cable.
I could bodge up and get some use out of it with a spacer but just wondered has anyone else had this issue?

Hi, It depends on what clutch kit you have used- there are several different kinds in 500s. Nuova and 500D use a Coil spring clutch originally with a carbon thrust bearing - there are two different splines and the fork is different to 500F models.
In 500F models there is a diaphragm type clutch and the clutch will interchange with a 126 style which runs a different release bearing. The 500F clutch cover had a spring loaded pad that the release bearing touches upon where the later style clutch has no pad and a much slimmer style of bearing that is thicker.
If you use a 500F bearing with a 126 clutch it will not have enough travel and probably will not disengage as the bearing is touching at the wrong part of the diaphragm springs.
The bearings look very different but should interchange on the release fork- if you can take some pictures of your components we should be able to help!

KNO_3004 by peterthompson, on Flickr

Thanks for that explanation Damon. The wide range of suppliers out there has lead me astray with a few bits and pieces now, as I tend to buy well ahead of need to economise postage.
I see now that I have probably got a 126 assembly. I think the suppliers mislead when they say "fits" 500 sometimes because so many of the cars have had the engines replaced these day that it is perhaps a little rare to have the original!
The replacement bearing does seem to have additional metalwork that would foul the forks.

Hi,
Yes as I suspected- it is a 126 style bearing. I would be surprised if the earlier style 500F clutch is readily available anymore and it is no better. You will need to use the new bearing and it should fit correctly on your existing fork. This design will only fit one way around- if you fit it as you have it shown on the picture with the bent section pointing to towards the heater duct and fit the securing clips it should work fine.
If you take a picture with the bearing mounted on the fork I will have a look before you pop the engine back in.
Regards
Damon

As you know Peter I have the same new release bearing as you and as I going to Ricambio to get a new gasket, I thought I would take it with me and see what Franko thought. We went through all the different release bearings he had there and what we have is the Polish manufactured 126 bearing, so it could be preceded by the word "cheap".

Other bearings he had there were Italian manufactured and looked quite different from the original and none of them had the little wings on them that ours have and if I remember correctly they were the bits that snag?????

But he did say that he didn't think there would be a problem using the old bearing, if it was ok, with the new clutch housing and plate.

As you know my engine has just gone back in with the new clutch and old bearing, so if you hang fire for a couple of days I should be able to tell you whether it works or not! If not it is gearbox back out for me.:bang:

Looks like I am going to have take my gearbox out again. I never doubted Damon for a moment but I was trying my best to hope it would work. :bang:

This thread here confirms what Damon said.

http://www.fiat500club.org.uk/clubchat/viewtopic.php?f=1&t=7666&hilit=Release+bearing

Great research Tony and many thanks to Damon and yourself. This is turning out to be a very useful forum so longs as you guys are around.

Ok well I undid the gearbox today and managed to squeeze out the old release bearing without fully having to drop the box. Squeezed the new one in got the box finger tight on the bell housing and realised I had the release bearing the wrong way wrong. So all apart again, refitted, checked the lever and smooth as a babies bottom. No snagging on the lever at all.

I took some pics for reference.

This is the old release bearing resting on the fingers on the clutch housing, it is at its most forward point, it was hardly touching them, so it would never have had enough travel to engage the clutch at all.



This is the new bearing or 126 bearing. It resting on the fingers but it is not at its most forward point of lever movement, also any snagging occurs on the lever movement happens way before the bearings normal position which would be resting on the fingers.