Topic: Clutch Question - Not another one...

[rogg]

Just picked up a bitsa on the weekend, 74 CB500 Frame with a 67 CB550 engine. Previous owner pulled the clutch apart and put together again, was working, now its not.

I have read the manual and lots on here. I'm wondering if I need to pull it apart to see if its been put togeher correctly. But have a question that might answer that. With the cable totally disconnected, should there be play in the lever outside the clutch?

I would have thought it would be fixed, or at least stiff to move when the manual says to set the adjuster (which I have done, but when its pushed up to where I think it should be resting).

See photos below, 1st one is slack, 2nd is if I push up and the dots line up.

When the cable is connected, and clutch lever pulled in, the leaver on the clutch housing does still move up as it should but doesn't disengage the clutch and I can't seem to adjust it either way to get it to work. Worried about this freeplay.

Thoughts?

[05c50]

Too much free play, something's not right inside.

......Paul

[rogg]

Thanks Paul, suspected as much, was hoping not.

I'll pull it apart tomorrow and have a look.

[dave500]

gday rogg,with the cable disconnected like that there will be heaps of slack on that lever,itll drop right down like shown,if the previous owner has fooled with it id be removing the case and having a look that it is assembled correctly if you cant get it to work,look here.
http://forums.sohc4.net/index.php?topic=135642.0

[rogg]

Pulled it all apart. Thought there was something strange about how there was no play at all in the plates. There were a few things put back together incorrectly.

There was too much play (or it was moving too freely) on the clutch leaver. This was because the spring that holds the clutch adjusting lever was sitting under the adjusting lever and not holding it against the case. That was fixed.

Also, the sleeve was on the back of the clutch housing. Not inside. This meant there was both the sleeve, and the spacer on the outside. So the whole housing was too far out from the engine.

It's still missing a shim (or washer) from under the snap ring. Is there a correct size? Where can I source one?

In the first photo, you can also see its missing one of the casing bolts... Will have to source some replacement ones of these also.

I also think my clutch cable is too long. I've totally used all the adjustment at the lever, and am on the last couple of threads at the clutch end. There is still play in the lever.

But, I got it working. The clutch works now. Managed to ride it up and down the street. Onto the next issue... Which i think is tuning / carbs related.

[dave500]

you want three inches of slack in the cable,if its obviously more you have the 500 one?

[Ecks]

The little screw and jam nut sticking out the bottom of the clutch cover will likely need adjustment.  Once you have all the parts assembled correctly, adjust the screw so that the dimple on the clutch arm lines up with the nearby dimple on the clutch cover at the point where the slack is taken up.  The usual cable adjustments should follow.

The shim you speak of comes in different thicknesses, the idea is to pick the thickness that sets the correct amount of free play.  I don't have my trusty Haynes manual in front of me, but maybe someone can chime in with the correct free play figure, and perhaps also suggest a reasonable shim thickness to start with.

Let's just hope that your PO didn't touch anything else than the clutch.

[rogg]

The PO had it for a year. He replaced the forks and headlight. Then gave up after the clutch didn't work.

So now it runs. But after a lap of the street it was warm. When hot, it dies on idle.

Also getting a bit of fuel on the ground when idling think it's coming from one of the carby nipples at the bottom.

Needs a good service and tune.