Topic: CB 500 Four (1972?) Full Restoration

[calj737]

That will be the cleanest bike in all of Oz, Mick. Slicker than a cookie sheet, one might say 

[MickB]

Thanks Cal for your comments, however it's a pretty dark photo, I think I'll take a day time photo.

[MickB]

Gear shift mechanism is in, can anyone tell me if it should go further in? It looks like it should, so the steel ball and cap and spring fit into the counter bored slot?

Thank you in advance

[MickB]

Can anyone help? Is this correct, I've checked workshop and clymer and can find nothing about correct position

[MickB]

After a couple of hours I think I've got figured out. The channel for the ball comes from the top duh! I was looking at it from the inside of the case!!

3 Questions

What length is the spring? Is it



Is this the collar for the ball?






What size is the steel ball?

Can some one please help.

[MickB]

Does the gearbox look ok?

[MickB]

I think this might be the collar the ball sits on?

[MickB]

Can anyone assist with some answers to some questions regarding the steel balls used in the clutch and drum?
What sizes are the balls used in the clutch is says#10, what is that in mm's?
What is the size ball used in the drum in mm's?
What is the length and width of the spring used in the drum stop?

Many thanks in advance

[2strokeTrush]

The steel ball just sits freely in the clutch cover, I purchased new ones from Honda 1.00$ (USA) but i dont remember a collar being i there. Could be though.  Gearbox looks good to me, no rust is a positive thing.  As far as going in deeper, the 500's clutches were known to have problems, so there is a way to fix it, but you have to keep going to find out what to fix.

[calj737]

Wrong part 2Stroke. He's not dealing with the cover, he's dealing with gear inside the Trans. Made the same mistake this am

[MickB]

Thanks you blokes, I was able to get 2 springs off eBay this morning. I just realised I don't need one, another newbie error, oh well just one more the the list.
Ball 1 is at the end of the clutch rod

Ball 2 is at the end of the Drum Screw

[MickB]

On CSMNL THERE AR 2 differing setups.



I have the setup in the bottom left of the picture, is the other a different model?

[MickB]

Picked up the 2 ball bearings for the clutch and drum.
New OEM horn arrived and new locks for seat, steering and ignition from Z1

[bryanj]

The spring and ball bearing were only used on the very early settup, if you have the two roller settup on the outside behind the clutch you dont use the ball and spring you need the later parts which are the bolt that just has a pin on the end (no hole for spring) and a loose collar that the pin fits inside and locates the selector drum.
If you look at a later parts book it will show you both settups

[MickB]

Thanks Bryan, what a great tip as I've been scratching my head about the spring. I have the bolt and collar but no spring (no spring is unusual as when I bought the bike in pieces I've had almost every part, in fact pretty much 2 of everything). I just shone a light in the hole and I don't need a spring at all only the collar and ball, there's not enough room to fit a spring as well as collar and ball.
I have this set up which must be correct for the '72 model? The 2 Stopper parts with little wheels on the ends

[bryanj]

No ball needed just the bolt and collar mate

[MickB]

Feel like I'm really starting to make progress - Finished putting the gearbox, primary shaft and crank into the bottom case. The engine is coming together finally! New bearings on primary shaft, other bearings were all good, new primary chain and new shock rubbers in the primary hub (rubber was Oddjob's recommendation)



Got Oil GuideB in ok.



But can someone please help - where does Oil Guide A go? I can see it's meant to go! I can see it on the schematic but that's it, I can't figure out where it fits.

[Bootsey]

This is from a 550, but I imagine they are the same. The bearing you can see is the one that the primary shaft goes into on the left hand side. You can see that plate and screw in front. Hope it helps

[MickB]

Thanks Bootsy

[MickB]

Got a bit done today,

After realizing Oil Guide "A" wasn't put in place (it's not clear in the schematic where it's to go) before I put the primary crank shafts in I used 2 magnets, 1 to hold it I place and the other a magnetized Philips head screwdriver I got in first go (it's now in the place where it should be.







Still have to fix up the kick starter and tomorrow I hope to put the cases together, with a bit of luck.

Bootsy was a big help today with answers to questions , as I didn't tear the engine down so I have no reference.

Is there anywhere (I can't find it) where it shows (with photos) a CB500 engine being rebuilt? The manuals are ok sort of but when you didn't put it apart it's really difficult.

[MickB]

Can anyone help as I'm having troubles getting the gearbox in and working

Is the drum shift in correctly, I can't get the front shaft to drop in place as the rear selector forks are hitting on the front shaft cogs?

Have I been sent to Coventry?

I can't find a post that covers this off, gearbox installation.

The shafts are in the upper case for ease (haha) of installation.

Is the drum shift in correctly?





Spins fine at present



See the position of the shift drum now



I can't get the front shaft to drop down into position.



Forks are hitting the cogs on the front shaft.

[bryanj]

Might sound daft but have you got the gears on the correct shafts in the right order and orientation---been there got the T shirt

[MickB]

Bryan thanks for your reply.
I think I've got the gears on the correct shaft and in the correct order including the washers,  but I'll double check.
I think the problem is in the shift drum, I've got it not in the correct way, either I'm 90 degrees out or something like that.

[MickB]

Had a win - found the part I was missing for the engine - tachometer drive

[MickB]

Got the gearbox and shift drum in and working.