Topic: Clutch lever modification CB500

[Deltarider]

The CB500 clutch is a bit hard to operate. Soon I will replace the too bulky Dyna by OEM coils to see if the modest change in routing of the clutchcable it brings, will result in some relief.
On the French site I've spotted an, in principle, intelligent modification. The pics speak for themselves, but for those who understand French: http://www.cb500four.com/fofo_cb500four/viewtopic.php?f=15&t=4747

[bryanj]

It will make an easier pull BUT will wear out the cable quicker due to angle of inner to outer

[Little_Phil]

Will you get the same amount of turn for the length of cable pulled at the bars?

[bryanj]

No

[Deltarider]

The man reports he has done over 2000km since the mod and enjoys around 50% relief. He can now operate the lever at the handlebar with 2 or 3 fingers. He has added 15mm, and calculated the max would be 20mm. Me personally I'd consider a bit less. No reports on extra wear.

[rotortiller]

All good so long as the clutch fully disengages with less push rod travel.

[Kenzo1979]

Man, my 500 clutch pulls like butter.  Easier than my 550.  Not sure if it’s the routing, length, lubrication of moving parts, or cable composition or maybe a combo of some or all, but I think a newborn with arthritis could pull it.  Wasn’t always that way, and it’s been so long since I fixed it that I don’t remember exactly what got it there but I’m pretty sure it was all about routing.  My bars are not stock and I think my cable may be a motion pro “minus X number of inches.”  In general when trying to find the optimal routing position, You can really feel the difference in the “ease of the squeeze” on clutches just by manipulating the cable while you pull the lever.  It’s amazing the difference a slight deviation can have on the whole feel. 


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[Deltarider]

That's why I will change the too bulky Dyna coils for the old OEM ones first and evaluate, before I'd make a modification to the 'arm' of the lever. BTW, can anyone measure the 'arm' of the CB550 lever at the clutch case? I am just curious if there's a difference in length

[MauiK3]

I can't see how less travel at the clutch end can work unless the original design was overkill in some way.

[Little_Phil]

Do a little calculation and guesstimating how much less turn you have. Restrict full movement of the clutch lever to give this lesser turn by taping a block to the bars. Try it out.

[Little_Phil]

The 550 arm is about 55mm centre to centre. But this is not the end of the story as there is another lever mechanism within the clutch cover that dials the movement down to a smaller amount. After all it is just about compressing four springs. I don't think the 500/450 mechanism is efficient at transferring the force. The mechanism is a hangover from much smaller capacity machines made by Honda that probably had weaker clutch springs.

[dave500]

that old corkscrew design was used over a lot of models,and i guess whilst cheap n easy on the smaller ones in the day as more horsepower had to be harnessed the release had to be improved aswell?i make 57mm on the centres,as phill mentions theres an internal cam affair that needs to be reckoned in?i think a lot of the old corkscrews got little grease in the day once out of Honda service?especially with that oddball grease fitting?