Topic: cb500 clutch too tight

[docoffey]

Iknow this is an old topic but I can't find the answer in the old threads.  First off, the rod is in one piece and appears to be in good shape.  The clutch was working fine until I took off the cover to inspect/clean the oil pressure switch.  While cleaning I pulled the clutch push rod and cleaned it as well.  No ball bearing fell out but I think it must be at the other end? I cleaned up the clutch actuator area too.  After putting it all back together the clutch lever is so tight I can't pull it. I've adjusted both ends of the cable to the full extent both ways.  when I just start the screws into the cover I can pull the lever.  As I tighten the screws the lever gets more and more tight. Of course I can't move the adjuster screw as it is frozen in. Even with the impact screwdriver.
Thanks for the help and sorry about bringing up an old and worn topic.  The bike only has 8000 miles on it so nothing should be worn out.

[calj737]

You're answering your own question. Was working, now it's not. You say the ball bearing is in hue he other end, but you haven't confirmed that. The clutch adjuster in the left can't be properly cleaned and working if you haven't located and installed the ball bearing.

Disassemble the left side, remove the actuator, locate and clean the ball bearing, and follow the procedure in the manual during disassembly and re-assembly.

The only real trick is to adjust the cable at the cover first then to fine tune at handle bar. When adjusting the clutch screw, just enough tension on the screw is sufficient. The remainder comes thru the cable adjustments.

[docoffey]

OK,  I finally got the adjuster to turn a bit and that has taken the tightness out.  Assuming the ball is at the other end, how do I get it out? I did nor see a ball come out when I pulled the actuator rod so I'm guessing/hoping that it's still at the other end. Have to put the carbs back on then I'll start it and check out the clutch adjustment.  I think I need to install a proper grease fitting at the adjuster, my grease gun won't "click" on to the original.
thanks for replying, I appreciate all the advice you folks give!

[calj737]

The ball should be on the left side, inside the adjuster. It will fall out if the inside of the adjuster is clean and not gobbed up with grease. If gobbed up, scrape out the grease and locate the ball. Then clean the adjuster and install everything again. Add some grease once adjusted if you're struggling that much to get it correct.

Understand the grease is there for ongoing lubrication not for accurate adjustment intially.

http://www.cmsnl.com/honda-cb500-500-four-k1-1972-usa_model460/partslist/E++11.html#results

[docoffey]

OH, I'll take the cover back off and make sure about the ball bearing.  Need to drill and tap for a grease fitting anyway.  also ordered some preformed float bowl gaskets.  Slight leaks around 2 of the bowls.  That blue gasket stuff is NOT impervious to gasoline!

[docoffey]

Well that's another good idea that didn't work.  The ball bearing was in place, imbedded in the grease. Drilling and tapping for a grease fitting turned into a real Charlie Foxtrot.  Quarter inch drill bit chewed out part of the internal metal so I attempted to patch it up with a piece of aluminum and epoxy.  If it ain't broke, don't fix it.  Grease from the fitting still leaks out arond the zerk inside instead of going into the adjuster.  Packed it by hand, looks like that will be the way to continually grease it until/unless I can come up with another cover.  Oh well, the clutch works nicely now and adjusts.
Thanks again for all the good advice!