Topic: Make Your Own CB500 Clutch Push Rod?

[SteveD CB500F]

As of this writing, CB500 clutch push rods are pretty much impossible to find anywhere. They come up on Ebay every now and then but sell for $50+.  That's just stupid for something that may well break again...

So, between Shifter19 and Number13 (seeing a theme here?):

Measurements for a Honda OEM pushrod are:

10 1/8 inches or 257 mm long
3/8 inch in diameter or 9.5 mm

[more recent info from Leafshutter:
had a broken one and bought a replacement
both are 255mm long and with a diameter of 8 mm]

You can easily fashion a push rod from
3/8" steel rod found at any hardware store.
The shifter side end should be ground flat and square,
and the brake side end should be neatly rounded in a semi-sphere
to mate with the clutch basket. If you err, err on the side of a bit too
long since this will allow you to keep the lifter mechanism low and avoid cracking.
May also be a good idea to quench harden the ends.

[MidTNJasonF]

Ok is this something that breaks frequently due to poor design? I am not familiar with it.

Anyone have a broken/bent one here in the US they would be willing to send me to test? If it is as simple as you say it would take me all of 20 minutes to set up the Hardinage and about 45 minutes run off a couple dozen of them from better quality material. My shop rate is $60 and hour so even with material costs they could still be dirt cheap.

[thanantos]

Has anyone actually done this?

I purchased some plate steel today from the hardware store to try. For quench hardening I assume you just head the end and then cool it quickly?

[davis96]

FYI: 3/8 is not the correct size, in order for this to work, the rod needs to be 8mm diameter (maybe 5/16)

[thanantos]

I found the same after I bought some 3/8" stock. A metallurgist friend of mine says we'll have to burn the zinc plating off to quench harden anyway which might make up the difference.

[AMD500]

did anyone get this to work??? in the market for one of these rods...

[plippo]

a friend of mine in italy makes them with very good quality materials, proper end radiuses for the sphere/ball conenctor and proper hardening.

http://www.ebay.it/itm/ws/eBayISAPI.dll?ViewItem&item=360368919533&clk_rvr_id=383055373804

[BigStanley]

I made one today out of two hardened Chevy 350 oversized pushrods. Just cut one down and welded the two together, easy peasy and didnt cost a dime. Works like a charm too.

[gmgarcia]

Hello,

This is a newbie question.

Would an aluminum rod work to replace the push rod assuming it's cut to the correct length and one end rounded? I think it's too soft and don't think it can be hardened easily, but I thought I'd ask.

Thanks,

[calj737]

Aluminum can work, just use a high grade of it. The downside to using aluminum is the ends will wear much more quickly than steel. Easiest to grab some stainless rod, round over end in lathe (or by hand with a bench grinder if you must).

[gmgarcia]

Thanks calj737, I'll work on getting some different materials.

[NobleHops]

Necromancing this thread, I am reviving a 71 CB500 (someone shoot me) and sure enough, it had a broken clutch pushrod! I was able to source one fairly easily, but that is mystifying. I did not find any other evidence of carnage as if a broken chain got to it or anything else, just a nice clean break about 4 inches in from where it should be.

More on that bike shortly, just for your entertainment.

N.

[JaredS]

Nice. Where from? I'm prepping a rebuild on my 72 500 and am acquiring parts to do so.

[NobleHops]

David silver spares