Topic: CB650 clutch case *boss* broke. w/ pics

[grasscutter]

Going over my 1982 CB650, checking it for a trip to Rockerbox in a few days.
Doing a routine clutch adjustment and when I loosened the nuts, the *boss* broke. 
Was probably broke, but the tightness of the nuts had been holding it together.

Pics show: 1- the break, 2- the piece, 3- me holding it with a screwdriver, and 4- one of my *repair*.

The repair is temporary.  Do have a spare parts engine that I'll pull the clutch cover assembly off when I get back.
But in my mind the *repair* should hold. 
I added washers (as you can see), to spread the load out.
Then drilled a small hole through the case material.  (does not effect oil, leaks, etc.), and wired it tight.

The clutch cable assembly does NOT fall out.  I did a test fitting before adding the washers, and even with the piece missing, it was not a large enough gap to fall out.

Thinking it should hold for 1200 miles! 
Second thoughts??

[K3Owner]

Not a 650 driver here - 550. Still, the nuts are not designed for a clamping function on my machine. The smaller nut is designed to lock the larger nut while the natural tension in the cable keeps the cable steady. If you use the smaller to tighten against the larger and the boss, you risk a snap of the boss.

So, damage done? Like I said, not a 650 guy. I guess you can mitigate by rigging it as you have but test it well before riding off for any great distance. I ran my VW for several weeks back and forth on a trip when 900 miles from home without a clutch so it's possible - but a pain the A$$.

Good luck!

[mono]

looks good, but if it fails, just undo your clutch lever and PULL REAL HARD.   maybe a couple zip ties as insurance to keep it in place?

[davesee]

mine has been broken like that for the last 20 000 miles or so...i think you're good.

[grasscutter]

K3owner:  Yeah, its likely been cracked for a long while.  Clutch adjustments are needed very often.  Funny you mention a VW reference.  Been a long time VW owner back when they were nothing but airheads!

mono:  Duh!  Zip ties.  Yeah, I'll make sure I've got a couple extra in my tool bag.

Davesee:  Yeah, I'm thinking I'm good.  Will stop after the 1st hour or so, and check.  After that.... fah-get-about-it!

[Brixie387]

I'm reviving this thread because I just suffered the same fate, only both ends of the boss broke off my bike - see pic.  Not sure what to do.  The solution shown by grasscutter probably won't work for me since I now have nothing to attach to.  Anyone have a brilliant solution for my dilemma?

[robvangulik]

Drill a couple of holes in the flat base of the boss, and screw a large washer against it, make a slit in one side and put the clutch cable back in place.....

[Brixie387]

Thanks for the tip robvangulik!  I did what you suggested and it seems to be a pretty sturdy fix.  I found another clutch cover on eBay for $25 and will probably switch it out at some point, but this should do for a while...

[mrfish2]

Thanks for the tip robvangulik!  I did what you suggested and it seems to be a pretty sturdy fix.  I found another clutch cover on eBay for $25 and will probably switch it out at some point, but this should do for a while...

I'm rebuilding a 650 engine for a project and ran into this same situation. For the price of a clutch cover off of ebay ($25 shipped for me) it was easier to just replace the cover instead of rig something up.

[robvangulik]

Thanks for the tip robvangulik!  I did what you suggested and it seems to be a pretty sturdy fix.  I found another clutch cover on eBay for $25 and will probably switch it out at some point, but this should do for a while...

The washer really only serves to hold the cable in the right place, the forces/strain of the cable are still taken up by the stump