Topic: 74 Cb 550 clutch shot?

[bryanbrady07]

OK just gonna get right into it but first providing some background info.

Specs: Bike is alittle over 13k miles.
4into1 exh.  Velocity stacks. idle jet stock (38) Needle middle notch.  Main jet: 115.

Made my first mistake by adding castrol 10w40 fully synthetic 4 stroke for my first oil change since my cafe racer rebuild. shortly after found out that this could lead to clutch slippage with wet clutches.   Took the bike out for a ride and it seemed to be a bit boggy from takeoff to 2nd gear sometimes 3rd with the throttle from 1/5 to 2/5. It would rev pretty high but be a big hesistant to takeoff until about 3/5 throttle.   (my assumption was some clutch slippage and possibly the jetting from those throttle positions i.e. partly the idle screw and needle position.)Then after that it would sound excellent and the pickup was great.  Shortly after the video which is really me riding and recording with my phone in my pocket, I got to 4th gear and the clutch then stopped engaging at all.  Pulled the bike over and there was total free play in the clutch lever and no matter how much i tightened the clutch cable could no longer switch gears.  Another thing to note was that during the rebuild and inspection everything was in spec according to the manual for the clutch so I did not replace disks, plates,or springs. The LEVER, CLUTCH ADJ. 22831-333-020 threads were stripped and was not able to adjust from the outside so I only adjusted via the clutch cable.  Before cracking the engine apart tomorrow and replacing the oil with 10w40 honda hpv semisynthetic 4 stroke,  has anyone experienced this before and what are things I need to look for and inspect?  Also if anyone has that lever clutch adjuster or knows of another year or make that fits mine,  Please let me know.

Thanks,
Bryan B.

[BomberMann650]

Flat spots in the rpm range are a fuel mix thing. 
Clutch slippage would cause the rpms to go up, and the bike may slow down.  Easily caused by improper oil type and a little bump in the road.

A stripped out adjuster ANYTHING gives rise to concern.

[bryanbrady07]

Ok so cracked the case and seemed to have immediately found the issue.  The ball on the inner housing side of the rod clutch lifter has broken off and was also stuck inside the plate clutch lifter.  Seemed pretty badly worn on the inside of the clutch plate and is not a cheap piece to replace. I saw another post that it was most likely due to the clutch cable being too tight which caused this warpage, but since I am unable to adjust from the outside due to my clutch adjuster screw being stripped, I need to adjust from the inside before putting the clutch cover back on. 

Obviously I will be ordering a new rod but will the plate be salvageable? If so what would be a recommended procedure? Also, looking out for a new adjuster if anyone has a spare. 

http://imgur.com/a/gASAn
http://imgur.com/a/UgkxM
http://imgur.com/a/OSnX8
http://imgur.com/a/dD9FV

[BomberMann650]

Wth happened with the adjuster lock nut!?!
That adjuster is absolutely necessary for clutch function.
I'm curious how the little rod ball got trapped and sheared off in there.  The part isn't even a tight fit.
With any luck you should be able to find a clutch cover and some extras bits n pieces on ebay.

[bryanbrady07]

The screw threads on the adjuster became stripped and i was no longer able to adjust properly and the locknut never was able to stay tightened down from the outside.  Luckily did some searching on ebay and found a complete clutch cover with the adjuster attached for 12$ as well as a new rod and plate for about 10$. 

[BomberMann650]

Good score.

Now which engine oil did you use again?

[bryanbrady07]

this is what i used at first     http://imgur.com/a/Fyovm

TT recommended using this so i got some and will add after my new parts come in.   semisynthetic  http://imgur.com/a/SQrLE

[BomberMann650]

TT is right to recommend the honda brand oil.
Last I checked, hondas lube contained significantly more zinc than castrol.
I'm a believer too.  My bike leaked like a sieve when running castrol.  Back to honda oil and the added zinc has helped the aging seals weep a lot less.

[540nova]

I've found adding Rislone zinc additive smoothed out my shifting significantly.


Sent from my iPhone using Tapatalk

[bryanbrady07]

While I have the clutch cover cracked I decided to order some new friction plates and inspect the metal clutch plates so I will decrease chances of any other problems arising in the future.  According to the manual, It says to use a feeler gauge but does not give any measurement.  Can someone please clarify as to what I am checking for or the proper procedure to go about checking for warpage?

http://imgur.com/a/oqiaX

[BomberMann650]

I grabbed a glass cutting board and set the metal rings on it.  If they stop flat, you're good.