Need clutch lever for Autohelm 4000

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Scott21120

Scott21120

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Oct 15, 2004
163
Oday 34 Wauwatosa, WI
Any chance anyone has a clutch lever for an Autohelm 4000 Mk I (the black wheel disc)? Mine is broken and Raymarine says they don't have anymore available. This is the original one that uses a roll pin to secure it - not a screw. They would like me to send the wheel unit in for repair, but I'd rather just find a lever than be without it for 2 weeks, and then probably having my only option be an upgrade that I don't want to pay for right now. Thanks, Scott
 
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Rick9619

Autohelm 4000 clutch lever

Scott, Your right, they are almost impossible to find parts for. Maybe google it and see if anyone has an old one you could part out. Or try Ebay. Once in a blue moon there. I had the same problem with mine and actually fabricated the pin and cam BUT, didnt trust it at sea. So I upgraded to the MKII. It is compatible with your control head. Has a way more user friendly motor and is put together better. You actually hose it out to clean it. You can pick one up on Ebay for 450 plus or minus. Besides, as soon as you fix the pin, the roller cams are gonna start breaking..... perhaps its time to upgrade, and not put a sizeable down payment on a MKII into fixing an old dog. Food for thought
 
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Monty Miller

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Feb 27, 2004
142
Hunter 29.5 Lake Travis, TX
I may have what you need

I have the complete wheel only the clutch needs to be adjusted. Give me a call. 512-346-2093
 
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Joe

Make a new one out of aluminum

After trying to get a new one I made one from 3/8 thick aluminum. All hand tools, nothing fancy. Follow the outer shape and the location of the flat in the hole. Split the end and drill a hole for a 4-40 screw and nut to pinch the slot closed on the shaft. Works GR8!
 
J

Joe

Here's the scoop

The shaft dimensions are (inches): .119 from the flat to the other side and .159 across the diameter. I traced the outside shape of the handle and marked the location of the hole and the flat at the same time. Then I drilled a #32 (.116) hole for the shaft. With a jewel’s file I put a flat (just eyeballed the width of the flat) in the correct location. Then just to make sure it would work (before cutting the whole thing out); I cut a slot in from the edge parallel to the flat to the center of the circle and about .25 inch on the other side of the hole. Then tried it on the shaft and it fit (tight). Just by filing the flat and cutting the slot the hole diameter opened up to fit the .159 shaft. Happy with the fit, I cut the outside shape, drilled and tapped a 4-40 screw hole perpendicular to the slot to pinch the hole closed, filed all the edges and buffed it up a bit. Just a note: you need to drill out one side of the 4-40 tapped hole to the clearance size so the screw only threads into half of the clamp. In my first reply I said I used a screw and nut but after looking at it this weekend I realized it was tapped. Hope this helps! Joe
 
Tim R.

Tim R.

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May 27, 2004
3,626
Caliber 40 Long Range Cruiser Portland, Maine
Raymarine Service

Last year I thought mine needed servicing and I called them. They said it would be about $100 for a new(or maybe rebuilt) unit. This is the whole clutch assembly. Tim
 
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