Topic: '73 500 Slipping clutch

[PsyKottok]

Trying to get this darned clutch straightened out.

Push rod was snapped, got lucky and found an intact one at the boneyard here (whopping $7!!)

Adjuster cup is broken, but does not seem to impede the action of the lifter (I looked, no replacement at the boneyard, and don't want to fork out $50 on ebay unless I have to)

Seems like the clutch has two states- dragging then engaged, or disengaged then slipping.

Meaning, if I get it adjusted to where the clutch fully grabs, its dragging at idle making it hard to pop into neutral among other unwanted side effects, or if I get it to where it is disengaged correctly with the lever pulled, it won't fully grab when I release the lever causing slippage under load.

Is there a trick to this? I tried adjusting the cup to where it barely contacts the rod, then pulled the slack out of the cable, but the cup seems to be too far counter clockwise.

New friction disks maybe? It seems to grab fine if I leave it loose enough though.

[calj737]

Did you also replace and install the steel ball bearing at the end of the push rod? IF yours was snapped, likely the ball fell out. And remember to grease that adjuster cup for smooth operation.

[PsyKottok]

Yes, the ball is still there, made sure of that, and I regreased the heck out of the cup and lifter. The new rod was a good 5mm or more longer than the old one i think that is what's throwing me off.

[Stev-o]

What shape is your cable in? If you dont know how old it is, replace it.

[Deltarider]

What shape is your cable in? If you dont know how old it is, replace it.

That ^^^ and did you follow the correct adjustment procedure starting at the adjuster in the cover, then the adjuster bottem end cable and then the adjuster top end cable at the handlebar? Do you have the correct cable? Honda had two different cables to accomodate different height handlebars. All this has to be checked first.

1 - Screw in the adjuster screw on the hand lever as far as possible.
2 - Screw in the case adjustment screw on the cable as far as possible (where the cable enters the side cover).
3 - Loosen the lock screw on the left side cover
4 - With a large flat blade or coin, tighten the slotted adjuster clutch as far as it will go. Then, back it off about an 1/8 of an inch
5 - Tighten the lock screw
6 - Screw out the case adjustment screw to take up slack
7 - If needed, screw out the hand lever adjuster to take up extra slack. Make sure to leave about 1/4 inch of free play in the lever
8 - Set the lock screw on the hand lever
9 - Set the lock nut on the case adjuster
10 - Go ride