Author Topic: Clutch won't engage cb500 (Read 2970 times)

vonvendetta · « **on:** October 26, 2014, 06:58:58 PM »

So I am almost done with the build and am having a hard time with the clutch. I attached some pictures to see. When I pull the lever I don't feel the clutch engage. When the bike is off I can go through all the gears without the clutch. I've checked the rod and it doesn't look broken. Am I just putting the cover on wrong or is the pin not going in all the way?

calj737 · « **Reply #1 on:** October 26, 2014, 07:07:33 PM »

Did you place the ball bearing in at the end of the rod?

vonvendetta · « **Reply #2 on:** October 26, 2014, 07:25:50 PM »

Ball bearing? That must be it. After a quick search I see I'm missing that.

dave500 · « **Reply #3 on:** October 27, 2014, 12:18:25 AM »

clean that oil sender connector aswell while the cover is off.

Bodi · « **Reply #4 on:** October 27, 2014, 04:22:22 AM »

Technically, that clutch is engaged and won't disengage.

Vinhead1957 · « **Reply #5 on:** October 27, 2014, 06:22:11 AM »

Looks like that wire got crushed from the cover. Fix that too

calj737 · « **Reply #6 on:** October 27, 2014, 06:26:47 AM »

Quote from: Vinhead1957 on October 27, 2014, 06:22:11 AM

Looks like that wire got crushed from the cover. Fix that too

Talking about the GREEN/RED neutral switch wire... Saw that too.

vonvendetta · « **Reply #7 on:** October 27, 2014, 07:28:48 AM »

Thanks vinhead, I'll make sure to fix that. Also had to order the ball bearing from Orlando since no one had it in stock, will let you know how it works later this week. The spring is looking a little rough too, anyone know a source or should I just buy a generic spring?

vonvendetta · « **Reply #8 on:** October 27, 2014, 07:36:33 AM »

Also, when putting the cover back on do I do anything with the clutch adjuster?

jmelche2 · « **Reply #9 on:** October 27, 2014, 04:45:01 PM »

I would make sure the lifter turns freely within the cover, so you can adjust the clutch. If it doesn't turn, tap it out with a rubber mallet and socket and clean things up so it is free. Also clean the adjuster, look for any cracks, lube and reassemble.

heyitsrama · « **Reply #10 on:** October 28, 2014, 12:05:27 AM »

Quote from: jmelche2 on October 27, 2014, 04:45:01 PM

I would make sure the lifter turns freely within the cover, so you can adjust the clutch. If it doesn't turn, tap it out with a rubber mallet and socket and clean things up so it is free. Also clean the adjuster, look for any cracks, lube and reassemble.

Hey look a thread that i was about to make for my own bike, uhh which way does this tap out, do i hit it from the inside of the cover,forcing the adjuster out of the outside? or the other way around? Mine seems to be stuck in the crank case cover.
i feel like its back to square one with this dam crank case on my bike.

dave500 · « **Reply #11 on:** October 28, 2014, 12:23:15 AM »

from outside inwards,soak it well first if you can.

heyitsrama · « **Reply #12 on:** October 28, 2014, 02:53:08 PM »

alright, so i tore apart the clutch adjuster, and regreased the crap out of it. It will spin counter clockwise, and move further inside the crank case cover, now I was wondering what else the issue can be. I have the rear tire up on the center stand, and it feels like i can depress the clutch down, but the wheel does not free spin when in gear? Is there any other part that I'm missing? How does this clutch adjustment actually work?

vonvendetta · « **Reply #13 on:** October 28, 2014, 05:05:43 PM »

Quote from: heyitsrama on October 28, 2014, 02:53:08 PM

alright, so i tore apart the clutch adjuster, and regreased the crap out of it. It will spin counter clockwise, and move further inside the crank case cover, now I was wondering what else the issue can be. I have the rear tire up on the center stand, and it feels like i can depress the clutch down, but the wheel does not free spin when in gear? Is there any other part that I'm missing? How does this clutch adjustment actually work?

Something I need to know as well.

jmelche2 · « **Reply #14 on:** October 28, 2014, 05:38:23 PM »

Quote from: heyitsrama on October 28, 2014, 02:53:08 PM

alright, so i tore apart the clutch adjuster, and regreased the crap out of it. It will spin counter clockwise, and move further inside the crank case cover, now I was wondering what else the issue can be. I have the rear tire up on the center stand, and it feels like i can depress the clutch down, but the wheel does not free spin when in gear? Is there any other part that I'm missing? How does this clutch adjustment actually work?

Do you have the ball bearing between the adjuster and rod?

heyitsrama · « **Reply #15 on:** October 28, 2014, 10:55:46 PM »

Quote from: jmelche2 on October 28, 2014, 05:38:23 PM

Quote from: heyitsrama on October 28, 2014, 02:53:08 PM
alright, so i tore apart the clutch adjuster, and regreased the crap out of it. It will spin counter clockwise, and move further inside the crank case cover, now I was wondering what else the issue can be. I have the rear tire up on the center stand, and it feels like i can depress the clutch down, but the wheel does not free spin when in gear? Is there any other part that I'm missing? How does this clutch adjustment actually work?

Do you have the ball bearing between the adjuster and rod?

yes sir, have the ball, and a solid, non broken push rod as well.

I just don't know how to set them all up. I assume you first set the adjuster, then set the cables? Im just not sure what to set the adjuster to.

dave500 · « **Reply #16 on:** October 28, 2014, 11:59:09 PM »

slacken the cable right off loose,with the case adjuster locking screw backed off turn that big slot adjuster clockwise till it stops,dont force it when it bottoms out,then just back it off about the slots width and lock it in place,then adjust the cable,you might need to readjust the case adjuster to suit,clockwise makes the clutch release earlier,counter clockwise makes it release later.

the terms of clutch usage often get confused,when you pull the clutch lever in toward the bar you are in fact releasing/disengaing the clutch,its not grabbing and driving anymore,when you slip the clutch lever out and start riding you are in fact engaging the clutch,its grabbing and driving the shafts,confusion with releasing the lever is actually engaging the clutch,the clutch is either engaged or disengaged,phew!so releasing the clutch lever is engaging the clutch,pulling the lever is releasing it.

heyitsrama · « **Reply #17 on:** October 29, 2014, 03:26:18 PM »

So apparently the adjuster had a crack in it, when i cleaned it up and slapped it back in it broke, and that was the main issue, I'm not sure if the clutch bolts were on too tight as well. I torqued them evenly to around 80 LB-inches, some of the crank case bolt heads are beginning to shear off. and i spilled a #$%* ton of oil in the garage when i forgot to cap the drain.

oh well the clutch works now. It needs a final adjustment. It seems that I have to pull the crap outta it, and it does not engage till the last inch.

alacrity · « **Reply #18 on:** October 29, 2014, 04:23:43 PM »

You can't make the bolts "too tight" if you have the proper length or OEM springs and the right number of plates and disks in the right order, the stock bolts will seat with normal firm appropriate torque for little m6 x 1.0 bolts. Torque specs in downloadable service manual. I have done two of these cb500s (which is prob 1% of dave500s number) and I would say this: a girl should be able to pull the lever to get the clutch to disengage. By comparison, the stock throttle pull takes way more muscle.

Sent from my iPhone using Tapatalk

calj737 · « **Reply #19 on:** October 29, 2014, 05:50:40 PM »

Torque for a 6mm bolt is 8#. Doubt your torque wrench reliably measures to it. Case bolts should be nipped up to firm, hand tight. Clutch springs need to be evenly torqued in stages to prevent snapping the plate.

vonvendetta · « **Reply #20 on:** October 30, 2014, 06:42:52 PM »

So I added the bearing and it now tries to disengage. When I put it in gear and I pull the clutch lever it will roll the bike bit with a lot of resistance compared to being in neutral. Should it be no resistance like neutral if I pull the lever in gear? I've tried to take the adjuster off to see if that is the problem but I can't get it to budge. Do I just turn it counter clockwise? Is there something else I have to do first?

heyitsrama · « **Reply #21 on:** October 30, 2014, 09:01:41 PM »

You put the bearing in? Which bearing did you install? I have a similar issue with mine, its that it spins with resistance. Im going to try to mess with the adjuster a bit more, because its a pain in the ass to pull the lever all the way down. It looks like I'm starting to damage the adjuster, what are you using so that it does not slip, and bend the metal around the adjuster? I turned mine clockwise like Dave500 said, until i got it to go all the way. I think it might be a bit more adjustable tho.

I assume that you should have a neutral level resistance, rather than it wanting to stop. can we get a person that has a working bike in here? hahahahaha

dave500 · « **Reply #22 on:** October 31, 2014, 12:19:20 AM »

pushing the bike in gear motor stopped and clutch lever pulled in there will still be some drag felt,try turning the big adjuster slot more clockwise?they can be finicky to get set so youll disengage but not slip under power,ive always found sand blasting the steels and new frictions always works if the frictions are old or unknown?new genuine springs are always worth the money aswell if your getting slippage,if you have the clutch cover off check the basket end float,ive always had more trouble with 500s than 550s getting the clutch happy,probably explains the update with the 550 engine?the male steel cork screw thread probably wears aswell giving less ramp effect lessening the clutch release?the zinc alloy female one is still available,being softer they'll be worn more of course.

iron_worker · « **Reply #23 on:** October 31, 2014, 09:22:13 AM »

My next step was going to be check for cracks ... looks like you found it.

IW

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Author Topic: Clutch won't engage cb500 (Read 2970 times)