Topic: 71 CB500 - this will be work

[cheddarGoblin]

This wheel was in terrible shape. I had never rebuilt an entire wheel before but that was about to change.



Removing the wheel bearings was not easy and it took quite a bit of heat.


Mostly a pic for reference before I remove the spokes.


Snip snip


They go everywhere when you cut them out. Made sure to count them to make sure I got them all out of the yard. Didn't want to find one with my bare feet.


I polished the hub as best as I could then re-laced the wheel while watching a movie. I probably should have replaced the rim but I didn't


I had to rig up a truing stand. Definitely not ideal but seemed to do the job. I would work on it for awhile over a few days in order to not rush it. I got it pretty straight, still seems to have a bit of hop. Many have to spend a little more time on it if it seem noticeable. I am pretty happy with how it turned out for my first time doing it.

[cheddarGoblin]

I had to do something about this battery box. I soaked it in vinegar to get rid of some of the rust then prepped it for paint.



These things were crumbling


Not sure how they are $3 a piece from 4 into 1 but they are.


Got it reinstalled and even got the battery strap that was MIA. The paint turned out fine, that is rust or dust from the crumbling seat on the battery box.

[cheddarGoblin]

I did not like the high handlebars. I should have replaced them before ever wiring them. Decided to replace them with the 550F Super Sport bars from 4 into 1.



I like these A LOT better.

[cheddarGoblin]

This seemed like the time to do something about this clutch cable.



In addition to the cable, I have some seals to replace in here.


I wonder how long that has been in there.


Where the cable connects looks a little mangled but not terrible


I started by just cleaning the cover




While digging out the old grease, I found a chunk of metal that I thought was just some road debris...


But as I kept cleaning, I noticed that this did not look quite right


Eventually found the clutch adjuster to be the source of the metal shards


It looks like this is a common issue with these bikes but finding a replacement might be a challenge.

[Shtonecb500]

you are correct, they are kinda hard to find and pricey, ill keep an eye for ya. Nice progress.

[Stev-o]

Nice work....

[RAFster122s]

Nice work, sorry to see clutch adjuster in pieces

[cheddarGoblin]

Guess I will start by removing the chain. I had to clean off some grit to even find the master link



I hadn't even noticed how this cotter pin was installed until now...


I didn't really like this exhaust. I like it even less now, can't get a socket on the axle nut.


Got the chain removed. Should probably just replace it but got other issues to handle first.


Gotta clean up some of this mess and then will start replacing seals. Sprocket has noticeable wear as well.

[cheddarGoblin]

The clutch pushrod just pulled right out. After reading some threads here, figured out that it is broken as well.


Removed the seal for the clutch pushrod. This is what it looks like behind the seal, the edge on this looks suspect but I don't see any broken pieces. Is something is wrong here?


I am not sure how to remove the broken portion of the clutch pushrod. Is there a way to get to it from this side or do I need to remove it from the clutch side?

[grcamna2]

How about using a powerful/small dia. magnet to remove the broken pushrod?

[Kelly E]

Plus 1 on the magnet, I have one powerful and small enough to do the job so they are out there. I can't remember what I got the magnet off of but I super glued it onto a magnetic retrieval tool from the parts store that had a crappy magnet. It's saved our butts so many times.

[HondaMan]

The clutch pushrod just pulled right out. After reading some threads here, figured out that it is broken as well.


Removed the seal for the clutch pushrod. This is what it looks like behind the seal, the edge on this looks suspect but I don't see any broken pieces. Is something is wrong here?


I am not sure how to remove the broken portion of the clutch pushrod. Is there a way to get to it from this side or do I need to remove it from the clutch side?

That seal you pulled out for is just showing you the transmission mainshaft bearing. It isn't broken: that's how they look when installed.
Some folks have welded the broken pieces of clutch rod together again: it works if the penetration is deep and the resulting surface is smooth.

A tip to the wise: the shaft seal on the shifter-shaft rod MUST be 13,8mm ID. Most of today's "seal kits" have a 14mm ID because it is standard and far easier to get: Honda still has the 13.8mm version for the 500/550 bikes. CMSNL will have them, too. If you just use the 14mm version it WILL leak oil out the shifter shaft when hot and parked on the sidestand: most people seem to think this is a sort of 'chain oiler', but it's just an oil leak.

[cheddarGoblin]

The clutch pushrod just pulled right out. After reading some threads here, figured out that it is broken as well.


Removed the seal for the clutch pushrod. This is what it looks like behind the seal, the edge on this looks suspect but I don't see any broken pieces. Is something is wrong here?


I am not sure how to remove the broken portion of the clutch pushrod. Is there a way to get to it from this side or do I need to remove it from the clutch side?

That seal you pulled out for is just showing you the transmission mainshaft bearing. It isn't broken: that's how they look when installed.
Some folks have welded the broken pieces of clutch rod together again: it works if the penetration is deep and the resulting surface is smooth.

A tip to the wise: the shaft seal on the shifter-shaft rod MUST be 13,8mm ID. Most of today's "seal kits" have a 14mm ID because it is standard and far easier to get: Honda still has the 13.8mm version for the 500/550 bikes. CMSNL will have them, too. If you just use the 14mm version it WILL leak oil out the shifter shaft when hot and parked on the sidestand: most people seem to think this is a sort of 'chain oiler', but it's just an oil leak.

Oh thank goodness!

I appreciate the response. I was looking for this and couldn't find anything in the parts fiche because I didn't know where to look. Once I looked at the transmission, I can see the part and that it does have that 'missing' piece. This was really starting to snowball so I am very glad to know this isn't another issue!

I did purchase a seal kit already, so will make sure to check the dimension of this seal and keep it mind if I end up with a chain oller

[cheddarGoblin]

How about using a powerful/small dia. magnet to remove the broken pushrod?

It's my understanding that the pushrod for this model is steel on the ends but aluminum in the middle. I am assuming it breaks where the two metal meet, so not sure I magnet will grab it. I did find a new pushrod so am waiting for it to show up so I can compare and see if that is the case.

[cheddarGoblin]

Not sure if I had to take the right side cover off to access the pushrod but that is what I did. Give the other broken parts, it seemed like checking out the rest of the clutch didn't seem like a bad idea anyway.


This pic is mostly just a reminder of where this washer goes

[RAFster122s]

Test your broken piece of clutch pushrod, if it is aluminum it won't be magnetic, but it wouldn't be magnetic if it were stainless as well...

The cb500 weakness is this clutch pushrod, very common failure, this the reason for redesign for cb550.

[cheddarGoblin]

Figured I would give this a polish while it was off.




Didn't go to crazy with polish but am happy with the result.

[cheddarGoblin]

I was able to get a clutch pushrod that is still in one piece from David Silver spares


It does have a spot that had some rust but it doesn't seem like it will be an issue.


I was also able to find a clutch adjuster that was in one piece and reassembled that part after giving the cover alight polish.



I am waiting for a right side gasket then cans replace some seals and get this all reassembled.

[Oddjob]

For some reason I can't see a single image that the thread starter posts, can see everyone else, seems a problem with Imgur to me or is that how Imgur works, you need to be registered to see them?

[calj737]

For some reason I can't see a single image that the thread starter posts, can see everyone else, seems a problem with Imgur to me or is that how Imgur works, you need to be registered to see them?

I’m not on Imgur and not having an issue. Laptop, tablet or phone.

[cheddarGoblin]

Gasket finally showed up so I can get this side reassembled.


All reassembled.

[Oddjob]

As regards the pictures, I can see them on my phone but not until today on my PC, they started off not there and then suddenly just appeared, strange. Posted a reply and then they were gone again. 

The clutch lifter mechanism, did you by chance remove the worm part and if so, below that is the hollow alloy piece capped with a seal enclosed in a metal fitting, did you remove that seal as most break underneath the seal and you can't see the damage as the seal is holding everything together.

[cheddarGoblin]

As regards the pictures, I can see them on my phone but not until today on my PC, they started off not there and then suddenly just appeared, strange. Posted a reply and then they were gone again. 

The clutch lifter mechanism, did you by chance remove the worm part and if so, below that is the hollow alloy piece capped with a seal enclosed in a metal fitting, did you remove that seal as most break underneath the seal and you can't see the damage as the seal is holding everything together.

Maybe the lack of pics is a browser issue. Not really sure.

Further up in the thread I found that the clutch adjuster was broken underneath that seal. I had found metal shards in the cover while cleaning it and eventually found it was from the clutch adjuster. I found a pricey replacement on eBay, and then had to replace the pushrod as well.

[cheddarGoblin]

I am almost ready to get the cover back on and try out the clutch without all the broken pieces.

I replaced the seals for the pushrod, shifter and countershaft. The pushrod seal didn't go in quite right, I piece of it looks bent over. It is right where there is some wear on the case where the chain had rubbed at some point. I don't like it but it does not seem to leak right after running the engine for a few minutes. I have a feeling I will make it worse if I mess with it more.

[cheddarGoblin]

I was able to get both engine covers reassembled without issue and finally install the new clutch cable (the only thing I started out wanting to do when I started out)


I have some new rubber around here somewhere for this. I had never seen a peg so bad before


I found the cotter pin had sheared off, so had to do a quick side quest.



Finally all put back together