Topic: Clutch issues - stuck clutch arm (CB550K3)

[shads]

My build is nearing completion and I just installed a new short clutch cable for clip ons.  I hooked it up today but was struggling to get it adjusted properly.  Ive read the manual and several threads on here on how to do it - I slackened the cable by winding in both ends of the cable before playing with the clutch adjuster.  I had back out the clutch adjuster all the way to get the marks on the arm to line up (whilst slightly pushing up on it), then with the adjusters on each end of the cable wound out as far as they would go I was able to pull the clutch arm but it didn't feel like it was fully engaging.  I tried changing the gears but could only occasionally get into first I think.  The gear changes felt very odd, I seemed to be able to change gear just as easy without the using the clutch as with it.

Then I messed around the clutch adjustment some more and tried routing the cable slightly differently as it felt quite heavy, but now my clutch arm is stuck at the bottom of the range of movement and wont move at all (previously I could move it up an inch or so up).   

The bike hasnt run since the engine was rebuilt and this is the first time ive messed with the clutch since taking the bike apart earlier this year.  Ive never ridden it or had the engine running so not sure how things should be when they are working correctly (im a noob in case you didnt guess).

I guess im going to have to pull the clutch cover off and see whats going on in the basket?  Any ideas?  Why would the arm now be stuck all of a sudden?

[dave500]

if the plates are worn youll never adjust it,might just need new plates?also check the basket end float,its shimmed and my need another added?

[bryanj]

You have screwde the adjuster too far one way and the mechanism inside the casing has "jumped" the cam

[shads]

Yep that was it, thanks!  I took the clutch cover off and put the arm back in the right place.

However I went to adjust it again and I can only get the marks to line up if I turn the clutch adjuster screw all the way anti-clockwise, and then lever inside the case jumped the cam again.  Does that mean my clutch is worn and I need a new one?  If so, I might as well do it now before I try to get the engine going...

 

[dave500]

pull on the basket in and out,does it move say one mm,or maybe half a mm?if so its too much,check that and replace the plates they'll last forever then,i run a david silvers kit ive thrashed for years and never had to re adjust it,ive really tortured this clutch and it just hangs on,done a lot of hard launches!

[shads]

Yep there is a little bit of play.  How does this look?  Too much?

[dave500]

i cant see it,cant be much?

[shads]

Its not a lot - probably about 0.5 mm or so...

[shads]

Decided im just going to replace the clutch.  I have the clutch that has the one thick B plate in the middle and ive spent all evening reading threads on here - my plan is new EBC friction discs (kit ck1146), 5 new Honda plates, keep the old thick B plate and new Honda clutch springs.