Author Topic: Mysteries of the CB500 Clutch...REVEALED! (Read 52975 times)

Lavis500 · « **Reply #50 on:** February 23, 2011, 04:11:10 PM »

After your post I looked because I was curious. This stuff looks like it would more than do the job.

http://www.aluminumrepair.com/video_new.asp

Actually looks pretty nifty. Could be the new thing for repairing stripped spark plug holes, too!

mjstone · « **Reply #51 on:** February 27, 2011, 02:20:44 PM »

So, of course, my push rod is broken. My question is, do I have to crack the cases to get the rest of the rod out, or is there a way to pull it out from the clutch side?

MJ

number13 · « **Reply #52 on:** February 27, 2011, 02:54:28 PM »

You will have to remove the clutch side case
to get the remaining piece out. It is a one beer chore.
Beware that some oil will come out, you may wish to
drain the crankcase beforehand.

mjstone · « **Reply #53 on:** February 27, 2011, 03:29:38 PM »

Thanks a lot, number13! I was hoping that this would be the case.

MJ

Jt550 · « **Reply #54 on:** April 20, 2011, 07:57:32 PM »

I figured I keep this tread afloat....

I just cracked into my project 500 clutch & noticed a few things I've read here.... Number 13 seems to have the most background and knowledge to share. So Im going to chuck these pics into the ring....

(( I also heard a myth that someone built a hydraulic version to fix all this crap..))

I guess I got lucky, Not to badly beat up......

Still looks hammered a bit... I guess I can still run it?? Isnt there a way to DIY a bash guard or even a simple redesign??

Rods in one piece, yet the ball bearing is fused to the rod..... Should I cut it off??

This wont move a mm" What to do??

Do I get it out from this side? I've read all I can, an have yet found the way to remove it... But atleast its not cracked! "yet."

dave500 · « **Reply #55 on:** April 20, 2011, 09:25:59 PM »

they pushout from the outside inwards.

Jt550 · « **Reply #56 on:** April 21, 2011, 02:34:08 AM »

Quote from: dave500 on April 20, 2011, 09:25:59 PM

they pushout from the outside inwards.

So what your saying is, "beat it inwards with a really big hammer..".
I'll give it a try, but that bugger really doesn't wanna move..

But thanks, now I know what direction to aim the mallet!

Oddjob · « **Reply #57 on:** April 21, 2011, 05:10:38 AM »

Might not look cracked but the round piece you can see on the inside is actually the seal, you may find it's cracked under that.

Check the length of the rod, if the bearing has fused to the rod it's usually an indication the rod has shortened as the end of the rod mushrooms out allowing the ball bearing to form a seal.

You may be able to bodge the cinch so that it still works, doesn't look to bad.

Clean everything like mad, make sure no old grease etc is still lurking inside the mechanisms and fit with new grease and lots of it, I'd fit a new pushrod seal as well, can't hurt and they do tend to weep after a while especially if the rod is moving around/flexing.

Socket the same size as the adjuster drum should protect it when driving it out.

Jt550 · « **Reply #58 on:** April 21, 2011, 06:26:41 AM »

Quote from: Oddjob on April 21, 2011, 05:10:38 AM

Might not look cracked but the round piece you can see on the inside is actually the seal, you may find it's cracked under that.

Check the length of the rod, if the bearing has fused to the rod it's usually an indication the rod has shortened as the end of the rod mushrooms out allowing the ball bearing to form a seal.

You may be able to bodge the cinch so that it still works, doesn't look to bad.

Clean everything like mad, make sure no old grease etc is still lurking inside the mechanisms and fit with new grease and lots of it, I'd fit a new pushrod seal as well, can't hurt and they do tend to weep after a while especially if the rod is moving around/flexing

Socket the same size as the adjuster drum should protect it when driving it out.

Thanks for the info, that's about the direction I was heading but it always settles the mind to hear someone else say it.. Good tips man, I hope that next guy reads this and can fix this pest of a clutch.

Plus if your method doesn't work, we can just curse your name torns the skys an let the cycle gods strike you down... Jk (next beers on me)

Keep it greasy....

number13 · « **Reply #59 on:** April 21, 2011, 10:01:43 AM »

Good advice from Oddjob. Those adjusters can freeze in there and be nearly impossible to get out, but try heating the area around the adjuster with a heat gun or a torch with a low flame, then flip the cover over and fill the adjuster with ice water. Once it is out a good polishing and some grease will keep it easy to use.
And that fused ball bearing is crazy! The PO must have really overtightened it.

Jt550 · « **Reply #60 on:** April 21, 2011, 10:44:21 AM »

Thanks 13, You are the 500 clutch Yoda... I'll give the icey/hot the shot... Keep your fingers crossed!

An did you ever give it any thought to a DIY bash guard of some type? Or is there just no clearance when that covers back on??

O! Whatta bout the mythical unicorn hydraulic 500 clutch??

strynboen · « **Reply #61 on:** April 21, 2011, 12:05:03 PM »

think it easy to take left handle from an small china cross bike,,with hyd back brake..and make an alu cilender to veld or skrev in hvere the old push rod vas sitting..and made an piston to push that chlutch..just use brake parts to make it
but are it possible to opdate to 550 chlutch..just to take an 550 side panel..and bolt on....?

number13 · « **Reply #62 on:** April 21, 2011, 12:19:26 PM »

I don't think there is enough room for a bash plate, but maybe you are cleverer
than me. I KNOW someone on this forum did a hydraulic conversion, but cannot find it for the
life of me. You can find generic hydraulic pusher setups all over e-bay, it is obvious how it would work, but of course you would need a small machine shop to get it to fit right.
Here's one:
http://cgi.ebay.com/ebaymotors/HYDRAULIC-CLUTCH-MASTER-SLAVE-00-06-RC51-RVT1000-MINT-/300533187459?pt=Motorcycles_Parts_Accessories&hash=item45f92c8383

dave500 · « **Reply #63 on:** April 21, 2011, 01:40:31 PM »

that adjuster will really seize up if its not kept greased,when you get it apart tap the grease fitting out and fit a proper type like this.

Jt550 · « **Reply #64 on:** April 21, 2011, 07:22:22 PM »

Viola!!!!!! Shazbot!!! ETC!!!!!!

Jt550 · « **Reply #65 on:** April 21, 2011, 07:28:51 PM »

Turbo Guzzi's CB500 Race bike.... He says that his tuner friend made it... It illuminates the worm gear. An it also looks like the clearance issue has been eliminated too.... Im attempting to get the information on it... An its a handmade one off...

dave500 · « **Reply #66 on:** April 21, 2011, 09:05:43 PM »

that looks good,well ELLIMINATED.nothing worse than a glow in the dark worm gear.

Jt550 · « **Reply #67 on:** April 22, 2011, 12:05:37 PM »

SORRY FOR THE HIGHJACK!!!
I HAVE FOUND THE WHITE UNICORN!!!!!!! AN ITS ITALIAN!!!!!
If you dig this!! Send all your praise to Turboguzzi...........

http://www.crispicorse.com/special/parti_speciali_frizione.htm
(((( There is some GREAT 500 bits! ))))

strynboen · « **Reply #68 on:** April 22, 2011, 12:18:11 PM »

damed ,,,presisly mine idea..somone was faster then me

jeff15116 · « **Reply #69 on:** April 22, 2011, 05:34:03 PM »

My clutch shifter rod broke and bent when the chain broke not too long ago. I've got the new rod but to get the old one out, I need to go in from the other side, huh? One ball bearing fell out on the garage floor and I can see another one still in there. Are there pics on here anywhere to show what it looks like from the right-hand side?

What else should I look to fix while I'm in there?

Oddjob · « **Reply #70 on:** April 25, 2011, 12:48:36 PM »

Sorry not my idea of a nice mod, looks damned ugly with the hydraulic line running down the outside of the sprocket cover. Not knocking the mod BTW, just the look of it.

I'm giving some serious thought to modding my 500 clutch lifter, I'm fairly sure I can come up with something much nicer looking and available to buy off E-bay as the parts I'm thinking of using are off a current Honda model. The clutch lever/reservoir even has the required mirror mount on it which is a big bonus.

number13 · « **Reply #71 on:** April 25, 2011, 01:32:24 PM »

A later model Honda used a very similar design, but instead of a screw lifter it
used a 3 ball and ramp design like the image below.
I always thought that would be a simple and effective mod.
I have one somewhere in my parts pile. I'll try
to dig it out and get some pictures.

Oddjob · « **Reply #72 on:** April 25, 2011, 01:57:37 PM »

Seen that somewhere before Number13, is it off a CJ250T by any chance. Doesn't look like a recent Honda as the engineering looks kinda dated

plippo · « **Reply #73 on:** April 25, 2011, 02:46:57 PM »

In case some of you interested in the clutch rod for the 500, a friend of mine in Italy has manufactured some very high quality repro, with C40 Steel, and heat treatments.
In italy is impossible to find the part, so he has commissioned some very good CNC made...

see auction.

http://cgi.ebay.it/ws/eBayISAPI.dll?ViewItem&item=360194715415

Jt550 · « **Reply #74 on:** April 25, 2011, 08:41:58 PM »

Quote from: Oddjob on April 25, 2011, 12:48:36 PM

Sorry not my idea of a nice mod, looks damned ugly with the hydraulic line running down the outside of the sprocket cover. Not knocking the mod BTW, just the look of it.

I'm giving some serious thought to modding my 500 clutch lifter, I'm fairly sure I can come up with something much nicer looking and available to buy off E-bay as the parts I'm thinking of using are off a current Honda model. The clutch lever/reservoir even has the required mirror mount on it which is a big bonus.

Hey Odd, its all good, I just wanted to get the damn thing to work right without chewing it self all to $h!t...A bash guard? etc.

But if you got another idea, swing for the fences and lay it on us... Im down to try anything... PM me if you need somebody to bounce idea's off of.. I might also be able to help with OEM Honda parts.... if necessary..

An 13... wtf... is that....? Im wracking my noodle trying to see how that might work...

$:-\$

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Author Topic: Mysteries of the CB500 Clutch...REVEALED! (Read 52975 times)