Author Topic: CB 500 Four (1972?) Full Restoration (Read 138503 times)

bryanj · « **Reply #550 on:** February 10, 2015, 11:30:12 pm »

The NOS sub loom I bought 15 years ago cost me $16 then and didn't come with the electric panel mate, think of the spare reg and rec that is with it

MickB · « **Reply #551 on:** February 11, 2015, 02:30:01 am »

The one I looked at was only a loom with nothing else

MickB · « **Reply #552 on:** February 11, 2015, 03:34:26 am »

BJ what's the eBay number?

Valhad · « **Reply #553 on:** February 11, 2015, 10:02:57 am »

Mick, I've not sent that sub loom from the 550 yet, still want it if you are making your own?

MickB · « **Reply #554 on:** February 11, 2015, 01:00:01 pm »

I'll let you know later today.

bryanj · « **Reply #555 on:** February 11, 2015, 11:18:08 pm »

Try this link

http://www.ebay.co.uk/itm/111595897998?ru=http%3A%2F%2Fwww.ebay.co.uk%2Fsch%2FHome-Furniture-DIY-%2F11700%2Fi.html%3F_from%3DR40%257CR40%26_nkw%3D111595897998%26_rdc%3D1#ht_54wt_958

MickB · « **Reply #556 on:** February 12, 2015, 12:37:00 am »

Thanks BJ

MickB · « **Reply #557 on:** February 12, 2015, 07:32:51 pm »

I'm finishing the gear lever side and thought I'd try the gears, I put the lever on 1st ok but then it couldn't get it to shift up (no clutch available as yet).
Do I need to worry?

bryanj · « **Reply #558 on:** February 12, 2015, 10:21:49 pm »

Both shafts need to be turning to shift through the gears

MickB · « **Reply #559 on:** February 12, 2015, 10:36:46 pm »

Thanks BJ

Also does this look correct?
When the actuator moves up it hits against the protector

When moved imitating the actuator being pulled by the cable.

The clutch cable seems to be too short, also, how much does the actuator lift up? Seems to be about 10mm,

With the spring at rest

The actuator's cable clip doesn't line up with the hole where the clutch cable enters the case

The actuator doesn't line up with the cut out (cutout seems to be for the clip to pass through).

Restoration Fan · « **Reply #560 on:** February 13, 2015, 01:41:10 am »

Quote from: MickB on February 12, 2015, 07:32:51 pm

I'm finishing the gear lever side and thought I'd try the gears, I put the lever on 1st ok but then it couldn't get it to shift up (no clutch available as yet).
Do I need to worry?

Mick,
I don't want to give bad advice here but the same thing happened to me. It turned out we had assembled the gears without having the bike in neutral. So we had to split the cases back open and reassemble it in neutral.

Once we did that, I'm able to shift through all the gears without even having the clutch on the bike yet.
Again, I don't want to cause worry but you would be better to find it out before you have everything buttoned back up and in the bike than go along thinking you're ok.

Ron

MickB · « **Reply #561 on:** February 13, 2015, 01:48:43 am »

Ron thanks, i was afraid that was the case however I hope I'm right but I think it was in neutral when I put it together. I could get it in first just sitting here, but no other gear.
BryanJ quote:-
Both shafts need to be turning to shift through the gears
[/quote].

Restoration Fan · « **Reply #562 on:** February 13, 2015, 02:04:07 am »

Quote from: MickB on February 13, 2015, 01:48:43 am

Ron thanks, i was afraid that was the case however I hope I'm right but I think it was in neutral when I put it together. I could get it in first just sitting here, but no other gear.
BryanJ quote:-
Both shafts need to be turning to shift through the gears

Yes, I saw that quote but wasn't quite sure what he was referring to by the "both shafts". I'm also not sure about the 500 because I don't have one. But it makes sense to me that it would be similar, if not the same to the 750's shift linkage. But I do know this...once we put mine back together correctly, I can shift it up and down through all of the gears.

As a reference, here's the link in our thread where we were dealing with it.
http://forums.sohc4.net/index.php?topic=141761.msg1645789#msg1645789

The key is that round piece that the shift arm connects to...the notch needs to be at the 10 o'clock position at assembly for it to be in neutral. If you haven't put your side cover on yet, how about a photo of the shift linkage assembly?

MickB · « **Reply #563 on:** February 13, 2015, 03:55:44 am »

RestoFan

Here's arm photos of the shift arm at 2 o'clock.

Restoration Fan · « **Reply #564 on:** February 13, 2015, 05:29:13 am »

Well, the 500 is definitely different than the 750 in the setup there. But there are similar components. If yours is assembled correctly, then your bike should be in neutral in those photos. Because that arm that's sitting in the notch at the 2 o'clock position...when the wheel on that arm slips into the notch, that's the neutral position there.

Since they're a different setup, you may be just fine. I'll let others who actually have worked on a 500 or 550 weigh in here because maybe there's something on one of them that makes it function different than the 750. But the purpose of that whole shift arm assembly is to rotate that wheel that has the notch in it. Because the other side of that wheel (inside the case) is the assembly where your 3 gear forks connect to the gears and rotating that shaft locks in a different gear. I would think that would be the same as the 750 personally and would still be slightly concerned if it isn't let me change gears.

bryanj · « **Reply #565 on:** February 13, 2015, 10:38:57 am »

You need to turn the shaft the clutch is on and the shaft the sprocket is on for the gears to in easily, if you think about it once the bike is moving both will turn nearly all the time.

As to the clutch operating mechanism it will (ok Should) never move far enough to hit the protector , also you need to read the book carefully about fitting the mechanism. There is also a bulletin posted here somewhere about the adjustment of the mechanism and where certain marks need to be for grease to get in and for smooth operation

MickB · « **Reply #566 on:** February 13, 2015, 01:23:42 pm »

I don't know what to do now, I hope I don't have to pull the engine down.
I'll get a drive chain and see if I can turn the shafts and engage each gear.

Restoration Fan · « **Reply #567 on:** February 13, 2015, 01:27:50 pm »

Quote from: MickB on February 13, 2015, 01:23:42 pm

I don't know what to do now, I hope I don't have to pull the engine down.
I'll get a drive chain and see if I can turn the shafts and engage each gear.

Definitely don't pull it apart based on just my recommendation because I'm basing my opinion on how a 750 works. Wait until someone who's worked on a 500 weighs in on that matter.

bryanj · « **Reply #568 on:** February 13, 2015, 03:25:59 pm »

You dont need a chain, just a third hand.
One to turn the sprocket
one to turn the clutch shaft
one to operate the gear pedal

Its worth trying just turning the sprocket and operating the gear lever at the same time as if you get things just right it will shift----just easier turning both at same time

MickB · « **Reply #569 on:** February 13, 2015, 05:51:13 pm »

Thanks BJ, I hope it works.

BTW looking at the photo of the gear change mechanism, is it in the correct position?

bryanj · « **Reply #570 on:** February 14, 2015, 01:40:14 am »

EVERY THING IS FITTED ok AND AT THAT POINT IS IN NEUTRAL MATE

MickB · « **Reply #571 on:** February 14, 2015, 01:46:27 am »

Thanks BJ it's good to know as I thought it was when I put it together. I did a fair bit of research on it but I'm glad you've confirmed.

I'll take off the clutch again and double check, alignment marks? I didn't notice any.

bryanj · « **Reply #572 on:** February 14, 2015, 09:30:10 am »

Sorry for previous reply, didn't notice till too late that my dyslexic keyboard had put caps lock on.

The marks I meant are on the sprocket cover casing and the big bit of clutch adjuster mech that shows on the outside

MickB · « **Reply #573 on:** February 14, 2015, 12:30:54 pm »

Bryan can you show on a photo?

MickB · « **Reply #574 on:** February 14, 2015, 09:46:18 pm »

My clutch rod is curved on both ends, does this matter? It's 257 mm x 8 mm.

Also how much grease goes in the clutch actuator?

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Author Topic: CB 500 Four (1972?) Full Restoration (Read 138503 times)