Topic: CB550 clutch adjustment issue

[tacc13]

I'm having a problem with the clutch not fully disengaging and followed all the tips on the forum with no joy. Looks like I'm not the first to get this.

What I've tried so far:
1. Slackened off the cables at both ends.
2. Aligned dots on arm and case and then backed off screw slightly before tightening the lock nut. (screw is almost fully anticlockwise)
3. Removed slack from lower end of clutch cable.
4. Adjust for about .5" of lever freeplay.
5. Bike goes into first but wheel is locked solid when clutch is in.
6. Tried with a fully warmed up engine and is the same.
7. Brand new clutch plates, soaked in oil (20W50).
8. New clutch cable.
9. Everything assembled by me, which may be the issue!

Is this likely to be a clutch assembly problem?  Anything else I can try before I pull the cover off?

Thanks for any advice. Just need to sort this then I can go for the first ride.

[jonda500]

5. Bike goes into first but wheel is locked solid when clutch is in.

errrr Please Explain???

[jonda500]

oh, I think I get it now, does it stall when you click it into first then?
John

[tacc13]

Yes it does.

I found a post from Hondaman about the new clutch plates being undersize compared to the original. My steel plates are new old stock but the fibre plates are EBC. Not sure if this is a problem.

Thanks

[Deltarider]

You did not specify your model which makes it hard to comment. Is it a 'F' or a 'K'? Are you aware the F clutch was modified? See part lists: http://www.honda4fun.com/materiale-documentazione-tecnica/parts-list/parts-list-cb550 . When did the issue begin? For how long has your bike been inactive? After hibernation all clutches are a bit hard to operate. Once the engine is warm, the problem dissappears.

[tacc13]

Bikes never been ridden. It's a complete tear down and rebuild from a wreck. Will check out the link thanks. Its a 76 550F. Any merit in putting it in gear and kicking it over with the ignition off? Thanks.

[Bodi]

If the plates are just stuck together from sitting too long, starting it with the wheel off the ground then revving it in 1st and hammering on the brake is the best way to free them. Tying the lever in for a day or three first might help. Won't do anything to fix a mechanical problem though.
I haven't heard of stiction issues with EBC clutch disks but I would use Honda if available.

[Kevnz]

Last year, I bought a non-runner 550 with the same issue, but not quite as bad as yours, it would lurch into gear and stall with the clutch pulled in. Stripped clutch and found nothing untoward ( mainly did this to see how the mechanism worked, as there doesn't seem to be a lot of adjustment) Long story short (ish), was brutal, got bike into gear without stalling and rode it a few km's and clutch freed up. Worked fine ever since. Ride along with lever pulled in and throttle on and off, you might get lucky.

[tacc13]

Thanks, it's definitely been sitting for a while since I bolted the engine back together. Will pull the lever back for a few days and then try the revving/braking thing to see if that helps.

[tacc13]

Decided to try cranking the kick starter with the bike in 1st and the lever tied back. On the third crank it pushed through and the wheel now turns. Still stiff, but definitely not locked, so I'm happy it's from lack of use and not a problem with assembly. Will leave the lever pulled back for a few days and then roll it around in gear before I fire her up on the weekend for the first ride.

[Kevnz]

Good result. I'm sure it will now free up properly with a bit of (ab)use.