Topic: So this is how you change a starter clutch on a cb550 W/O splitting the case!!!!

[Stev-o]

Great write up, smooth one.

[Tews19]

I started this journey this morning. Here is where I stand as I am not sure what pin I remove.

[Tews19]

Removed a few parts. The very bottom pic had a pin but I am not sure if it's the one smooth is talking about.

[wowbagger]

I think he's referring to the starter shaft pin (part # 2 on the fiche) in the case. Here's photos from my 500 but it should be the same.
http://www.cmsnl.com/honda-cb500-four-k0-general-export_model14652/partslist/E12.html#results

The first is with the case split looking at the top half. The second is a closeup of the bolt with the retainer washer and the third is your photo marking where you should be able to reach it from.

[wowbagger]

Just found a shot of it in your photos

[Tews19]

Thanks Bagger. I got it all out. Took a few minutes of wiggling but she is out. I think she is in good shape. How do I inspect? First pic is of the pin and where it was. Second pic is how the starter clutch looks. Now this is out of the 77 550 I'm parting out. There shouldn't be an issue swapping it into the 75 correct?

Also the entire process took roughly 2 hrs. I had to drill out several bolts though. I think I will order new gaskets and start the break down process on the 75 550 this afternoon or tomorrow.

Thanks Dave for showing me this thread and XSmooth for doing the process and documentation!

[Thekramer666]

 ???Why does the pin and starter gear needed to be removed  I followed this thread and just slid the chain off my starter clutch wiggled it out no problem at all unless It shouldn't have been that easy, I still got mine apart waiting on few screws should be assembling tomorrow just seeing if I really need to remove the pin and such

[Tews19]

You are replacing just the screws? MiNE was toast so I had to swap out entire assembly

[Thekramer666]

Well I pulled the starter clutch out the 3 screws that hold it together is what sheared so yea im just replacing the pins springs and those 3 screws that is what was spinning my starter works fine

[Thekramer666]

Ill triple check that's still good in mine I suspect the screws just came loose they didn't seem to have any threadlock on them so that's probably why it happened we will see come tuesday or wednesday when I reassemble damn I need a garage haha on a side note I may have located a second gas tank in my pops junk filled garage

[Thekramer666]

???Why does the pin and starter gear needed to be removed  I followed this thread and just slid the chain off my starter clutch wiggled it out no problem at all unless It shouldn't have been that easy, I still got mine apart waiting on few screws should be assembling tomorrow just seeing if I really need to remove the pin and such

I'll answer this question myself it needs to be removed for more clearance to put the clutch all back in if u don't you'll sit there trying forever hahaha like I did til I took the pin out n moved the starter gear up that little half inch is a gift of the gods

[RodGuy666]

I know its been a few years since this was posted but I'm about to try this out.. After going through the comments I have one question, if I use a threaded bolt to remove the primary shadt from the clutch side, do I even need to remove the oil pump?

Thank you,

[bryanj]

Its a good idea as you can damage the oil pump gear putting the primary shaft in as its not a free fit whilst you can rotate the pump body to mesh the gear on other side

[scottly]

you are a #$%*ing legend,this post should go straight to the faq section,,youve done it,,i said it was a #$%*ing fiddle but it can be done,,i wonder how many dealer ships have pulled the engine and split the cases?and charged the customer?good on ya xman!!heres a cyber beer for you.

I agree Dave.

[bryanj]

That split assembly is the primary cush drive and those rubbers, whilst expensive, are well worth replacing as they go like rock and shrink

[Kenzo1979]

I know its been a few years since this was posted but I'm about to try this out.. After going through the comments I have one question, if I use a threaded bolt to remove the primary shadt from the clutch side, do I even need to remove the oil pump?

Thank you,

Just remove the oil pump it doesn’t take long. Do the steps exactly as the post says , just use a small drift/punch to tap out the primary shaft, it comes out pretty easily. I’ve done this to three bikes now.

[Kenzo1979]

If you’re doing this for the first time, the hardest part is finagling the clutch assembly out of the bottom and off of the primary chain. Just keep wiggling and dancing it and after you curse 1000 times and swear that it can’t be done, it just magically pops out eventually.  But you have to curse a lot and you have to give up a few times and once the honda gods see that you believe it’s all a lie and you’re frustration has appeased them, It just falls out.

[scottly]

Just keep wiggling and dancing it and after you curse 1000 times and swear that it can’t be done, it just magically pops out eventually.  But you have to curse a lot and you have to give up a few times and once the honda gods see that you believe it’s all a lie and you’re frustration has appeased them, It just falls out.

Thanks for the laugh, Kenzo!

[Dr. Frankenstein]

Well - he's not 'wrong'...

[Kenzo1979]

Here are some other tips and things to look out for from my experience:

You may find that the one or more of the three screws holding the assembly together have damage.   So be prepared to possibly change one or more of those out.  These are the screws with the score marks to keep them from vibrating loose.  When you reassemble it, I recommend putting some thread lock on those screws and score them again if you can.   

Other things to look out for is broken springs and dowels; more than likely if you’re doing this, one of those dowels flew out got chewed up and is sitting in your oil pan. So definitely have replacements for those. I have seen springs that look like they are intact but actually had a section of them broken off so make sure all of your springs are the proper length.  Then there is the case holding everything together with those previously mentioned three screws…I have seen the lip of this case, bent up where the roller slipped out, you may need to take a hammer and bang the plate back down carefully in those areas to make sure it is holding the dowels in and not allowing them to escape.  Don’t go too far because the plate can also make the dowels seize if they are indented too much.  Flick them back-and-forth after you get it assembled by compressing the springs and letting them go to make sure they’re all moving and not popping out.  Lastly, I would slather some engine assembly lube on everything when you put it back together… the clutch assembly, the primary shaft, the starter motor gear, etc.   It also pays to have a second  set of eyes and hands.

Good luck.  It’s honestly not that bad if you’re paying attention to everything and doing everything in the right steps.

[HondaMan]

...and once the honda gods see that you believe it’s all a lie and you’re frustration has appeased them, It just falls out.

Hey, I've met those guys before!

[Kenzo1979]

I’m about one year plus into the phase of my life where I now need reading glasses. And I never have them on me.  Looking back at this post, I don’t even know who resurrected the thread or why? I think I was directing my comments to a person who posted about five years ago.    Well, whoever is dealing with this repair right now, good luck!

@Hondaman…I’m sure you do

[scottly]

I resurrected the thread when the question came up again, and moved it to Tricks and Tips so it would be easier to find in the future.

[Kenzo1979]

Scottly,  thank you.  Good move.  It is a very important and somewhat common repair.  Kudos to the original poster as well.

[scottly]

Here's the thread that prompted the resurrection, in case you're interested:
http://forums.sohc4.net/index.php/topic,206019.0.html