Author Topic: Clutch is RIDICULOUSLY difficult to pull after replacing, dragging? (Read 6545 times)

NastyNip · « **Reply #25 on:** February 20, 2014, 11:56:59 AM »

So sorry about the delay, work has been crazy.

So I swapped EVERYTHING (springs, plates, clutch cable, oil) to OEM parts and now I can just baaaaarrely adjust the case adjustmenter so that it's just about not dragging when I pull the clutch lever (the adjuster is maxed out, as well as the lower and upper cable adjusters are backed out as well). However, the friction point is almost non existent and the clutch fully engages after about a few mm of let up.

Also, after riding about 10 minutes and the bike is warmed up the friction point changes to where it starts dragging to the point where I can't shift anymore.

I'm completely out of ideas. Any thoughts? My only thing is that I don't think I have a thrust washer (14 on the diagram http://www.partzilla.com/parts/search/Honda/Motorcycle/1978/CB550K+A/CLUTCH/parts.html), do you think that would be of any significance? I don't think I had one before and it was working fine.

I'm at my wits end

LesterPiglet · « **Reply #26 on:** February 20, 2014, 12:27:56 PM »

Maybe the case adjuster has been installed incorrectly. Maybe a tooth out. I can't remember offhand if this is possible but worth looking in to.

Bailgang · « **Reply #27 on:** February 20, 2014, 02:44:45 PM »

Good advice so far so I can't really add to it however I highly doubt it's the EBC springs that are causing the problem unless they're the wrong springs. I installed a set of EBC springs on my 550 with it's original clutch and it was only marginally stiffer to pull the clutch in when it was all together compared to the original springs.

NastyNip · « **Reply #28 on:** February 20, 2014, 03:28:03 PM »

Quote from: Bailgang on February 20, 2014, 02:44:45 PM

Good advice so far so I can't really add to it however I highly doubt it's the EBC springs that are causing the problem unless they're the wrong springs. I installed a set of EBC springs on my 550 with it's original clutch and it was only marginally stiffer to pull the clutch in when it was all together compared to the original springs.

Yeah to confirm this: I ordered OEM springs to replace the EBC springs because I was running out of ideas and after installing the OEM there was a negligible difference in the pull, so I don't think that was the factor. There is something mechanically not right with this clutch set up, and it's driving me crazy because it's literally just a factor of not being able to adjust the clutch correctly. GRRRRRRRRRRRrrrrrr

dave500 · « **Reply #29 on:** February 20, 2014, 11:05:59 PM »

man im out of ideas without seeing it?throw it on a plane and come over,bring some beers.

Don R · « **Reply #30 on:** February 21, 2014, 10:40:34 PM »

Are the steels new? if not, are they warped from slipping on the old clutch? Any blue spots?

Patrick · « **Reply #31 on:** February 22, 2014, 08:26:52 AM »

It is really difficult to diagnose an issue like this from afar, but I cannot help but think something must be assembled wrong. Are you sure you have that convex washer pointed the right way? The middle rises outward. I've read over the thread and can think of nothing else to try. Clutches are supposed to be pretty easy....

NastyNip · « **Reply #32 on:** February 22, 2014, 12:10:20 PM »

Quote from: Patrick on February 22, 2014, 08:26:52 AM

It is really difficult to diagnose an issue like this from afar, but I cannot help but think something must be assembled wrong. Are you sure you have that convex washer pointed the right way? The middle rises outward. I've read over the thread and can think of nothing else to try. Clutches are supposed to be pretty easy....

Are you referencing #2 here? (http://www.partzilla.com/parts/search/Honda/Motorcycle/1978/CB550K+A/CLUTCH/parts.html)

That guy is put in correctly.

dave500 · « **Reply #33 on:** February 22, 2014, 02:07:13 PM »

youll have to take it apart again,you might spot something glaringly obvious?

Patrick · « **Reply #34 on:** February 22, 2014, 02:34:22 PM »

Not No. 2, Nasty. No. 18. But Dave is right. You need to tear it all the way down and install it all again. Sometimes it is something easy that just slipped by you. At least, that happens to me all the time.

Patrick

LesterPiglet · « **Reply #35 on:** February 22, 2014, 02:38:48 PM »

#15 I think you mean.

Patrick · « **Reply #36 on:** February 22, 2014, 02:43:59 PM »

I don;t have a torn down clutch in front of me, Lester, but is is certainly one of those two. The black one.

LesterPiglet · « **Reply #37 on:** February 22, 2014, 02:45:05 PM »

#18 on the list is a circlip.
I had to get my manual out as this conical washer thing had me wondering.
There isn't a conical washer, it is a shim that can be installed any way round.
The only thing to note in the assembly is that the last friction plate to be installed is smaller than the rest.

NastyNip · « **Reply #38 on:** February 22, 2014, 05:34:06 PM »

Quote from: LesterPiglet on February 22, 2014, 02:45:05 PM

#18 on the list is a circlip.
I had to get my manual out as this conical washer thing had me wondering.
There isn't a conical washer, it is a shim that can be installed any way round.
The only thing to note in the assembly is that the last friction plate to be installed is smaller than the rest.

Yeah I've taken the pack apart ~7 times in the past 6 months and am pretty good about getting the order correct in the stack.

The circlip and shim are there correctly.

I don't have #14, the Thrust Washer, but again I didn't have it before, so I don't know what the deal is.

dave500 · « **Reply #39 on:** February 22, 2014, 05:51:02 PM »

the deal is that you need one,the back of the clutch basket and the primary gear run close to the shifter mechanism as it is.

LesterPiglet · « **Reply #40 on:** February 22, 2014, 06:09:08 PM »

It's called a thrust washer for a reason.

bjbuchanan · « **Reply #41 on:** February 22, 2014, 06:29:35 PM »

Looking thru your thread and seeing your mention of the thrust washer before, you GOTTA HAVE the thrust washer. I wish I had checked this post out earlier, would have saved you some grief. That thrust washer sets the depth of the basket. Otherwise it will sort of just float, mixed results, who knows how it will work.

You gotta set the thrust washer in first, before the basket and everything. Post up a WTB for the washer

NastyNip · « **Reply #42 on:** February 22, 2014, 07:02:33 PM »

Is it a honda specific part? I ask because no places have it in stock online, and I doubt I will be able to find it used otherwise. If it is a standard spec washer, maybe I can just find a replacement at a hardware store?

dave500 · « **Reply #43 on:** February 22, 2014, 09:40:04 PM »

its a hardened precision machined spacer,you hardware store might have a lumpy zinc plated one?or use a stack of stainless ones with stamped out burrs?,this thing spins and takes all the end thrust when you squeeze the clutch lever,just get the real part man.

bjbuchanan · « **Reply #44 on:** February 22, 2014, 09:42:10 PM »

Quote from: NastyNip on February 22, 2014, 07:02:33 PM

Is it a honda specific part? I ask because no places have it in stock online, and I doubt I will be able to find it used otherwise. If it is a standard spec washer, maybe I can just find a replacement at a hardware store?

Like I said, post a want to buy on the forum. I can guarantee you will get the washer at a rate way better than buying, fast too. It is gonna be too thick for a single washer, too unique in size for some easy pop in and run deal

dave500 · « **Reply #45 on:** February 22, 2014, 10:20:00 PM »

its a discontinued part,even my hero david silvers doesent have it,theres a lot to said for buying cheap dead engines just for pins/bushes and spacers?

Fritz · « **Reply #46 on:** February 23, 2014, 02:56:40 PM »

Hi NastyNip,

cmsnl.com has the part that you are looking for (90455374000). It's in the Netherlands, so I would go on looking for one near you. I cannot believe that CMS has these washer but you can't find them in the US.

NastyNip · « **Reply #47 on:** February 24, 2014, 11:00:45 AM »

Hi all,

First, just wanted to say thanks a bunch for all the suggestions from everyone so far, it's awesome that we have a community like this where we can shoot the crap and I soak up awesome knowledge from those much wiser.

I did some more digging and by crazy sheer luck there was a thrust washer on sale on ebay, and should be arriving this week so hopefully I can install it this weekend with fingers crossed.

I'll follow up with what the results are

Clasico · « **Reply #48 on:** April 15, 2014, 11:35:22 PM »

Went over the hole post as i've a stiff clutch as well.
What happen when you installed the washer???

InTheStreet · « **Reply #49 on:** April 16, 2014, 03:45:38 AM »

I may be mis remembering, but I'm pretty sure my clutch is more inclined to drag when I turn the screw counter clockwise. Turning it clockwise helps it disengage.

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Author Topic: Clutch is RIDICULOUSLY difficult to pull after replacing, dragging? (Read 6545 times)