Topic: Clutch is very tough, what to do?

[Frijec]

Already tried to search for this, but couldn't find anything relevant. Sorry, if there is.

I've done a complete run through of my 1973 Honda CB 500F, carbs, oil parts, ignition etc.

My small issue right now, is that my clutch is a little tough to pull. So after an hour or so of riding my hand gets shooting pains, is there anything to do, to smoothen up the clutch and make it easier to handle?

[bwaller]

Have you disassembled the actuator, cleaned & regreased. Check the pushrod is in one piece.  Only once I tried an aftermarket clutch cable and it was #$%*e, the OEM cable was instantly appreciated. Are there aftermarket gorilla clutch springs in it? Remove the lever, clean & grease it too.

It should not be difficult to pull, an hour or two of simple maintenance and you too can enjoy what Honda intended! 

[camelman]

Check the cable routing too. Any sharp bends will make it very difficult to pull.

[Frijec]

I've already put on a fresh OEM clutch cable, it gave a little but not much. Also checked the routing and it is fine.

I think the spring is some random one, so I will try to find a correct OEM part. Will also have a look at cleaning the lever too and greasing up the cable

Thank you both!


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[Deltarider]

greasing up the cable

Better not, OEM cables have a Teflon lining and that doesn't like grease or oil.

[Frijec]

Hah, okay

Do any of you know where to find  the spring? Tried really hard to find it...


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[Honda Alan_UK]

I've just had the same problem. In the end I replaced the cable with a genuine Honda cable (from 4into1), stripped and cleaned the mechanism under the left hand side casing, and checked the ball bearing for wear. It's now better than ever.

I've read that the ball bearing can become 'flat spotted' and sometimes needs replacing.

Apart from this, just check the adjustments and then maybe the clutch housing itself.

Alan

[mystic_1]

Which spring?

If you mean the little spring on the return arm under the clutch cover, that spring doesn't really contribute to the pull required at the handle, it just takes up the remaining slack on the cable when you let go of the lever.

The four big main springs deeper inside the clutch housing are really what you're pulling against.  It's not impossible that someone may have upgraded them to stiffer springs at some point.

mystic_1

[camelman]

Do you notice inconsistent clutch engagement, occasional false neutrals, or difficulty shifting? If so, then your clutch basket fingers could be worn. That can create a lot of extra work to move the clutch, which would make it hard to pull the lever. I'd check all the external stuff first though.

[RRRToolSolutions]

I'd also look at the push rod to be sure it's not bent or has build-up that will tear the seal. Also make sure the ball is still in-place. If all of the components are straight, clean, and lubricated - there should not be a lot of resistance. I have used heavy springs from Fast by Gast and Barnett in my Kawasaki H2's and one CB500 without the problems you're having. You can compare your parts to a fiche and check to make sure you have them correctly assembled.

Does the cable slide easily without being attached? Is the 6mm bolt and busing in-place and in good shape at the handlebar pivot? If yes on these, then your problem is likely in the sprocket cover components. Post some pics if in doubt.

Regards, Gordon/RTS

http://www.rrrtoolsolutions.com/index.php

[heyitsrama]

Does the infamous 500 pushrod break from impact on a loose chain in the crank case?