Topic: How I broke my clutch

[kpier883]

Well I recently ordered and received Vesrah clutch springs from Cycle Recycle Part II.  They arrived in a timely manner.  I used the old adage that "Instructions are for people who don't know what they are doing" and went to work.  Taking things apart wasn't a problem.  I noticed that the new springs were about 3/16" longer than the old ones.  Also noticed that the bolts that go through the holder and springs were too short to reach with the new springs.  By pushing really hard on the bolt with the ratchet I was able to start one bolt then another on the opposite side.  Then I messed up.  While tightening I apparently got one side tighter and broke the flange of the cast piece that holds the springs in place.  Bad. 

Fortunately there was an auction ending the same weekend on a popular auction site where I picked up a used piece to replace the broken clutch part and a finned clutch cover to boot.  After receiving the new parts and cleaning thoroughly I READ THE MANUAL and BOUGHT A TORQUE WRENCH!  By FOLLOWING THE INSTRUCTIONS I achieved a more satisfactory outcome.  Amazing! 

One thing not in the instructions that proved useful was to use a longer bolt from the clutch cover to start compressing the springs.  I used two long bolts then was able to easily start the other two correct bolts.  Then I removed the long bolts and replaced with the correct bolts.  This was much easier than trying to start a short bolt while compressing the spring.  The manual stated that one should turn each bolt one turn and proceed to the next bolt to tighten one turn.  This pulled the components down in a straight fashion and avoided placing undue stress on the parts.

Finally, when the bolts were all hand tight, I employed the torque wrench and tightened the bolts one turn each with the torque wrench in order until the desired torque - 7 ft lbs or 84 inch pounds was achieved.  Whew.  I was proud to finish without breaking anything.

Maybe next time I'll read the manual first.  There are lots of ways to learn.  I just seem to learn the hard way too often!

Weather has been too cold for anything but a trip through the neighborhood but I am looking forward to testing the new springs under heavy throttle.  Previously the clutch would slip in the upper 1/3 of the rpm band under heavy throttle.  I will post an update once the test is done as to whether the problem is resolved.  If not, it will be time for clutch plates.

[KB02]

been there, done that, feel your pain.

Only I DID read the instructions first.. I just happened to miss-read them a little and wound up with the same result.

measure twice, cut once!! 

[byidesign]

I know how you feel, I usually do that{mess up} when not allowing
   enough time to work on things, and start to rush
      {Mr.Murphy steps right up to the plate}
           Now I wait till i have enough time, or learn to walk
      away, and come back later {after reading the directions}
         of course...

            Bruce

[kpier883]

Rode to work today and the clutch slip is cured!  There is this one left hand turn where you accelerate up through the gears.  There is a hump in the road that with a hand full of throttle in third gear the clutch always slipped before.  Went right through this morning without a slip.

All is well that ends well as they say...

[needswork]

Way ot go kpier.
I think my 550 is due for clutch work as well-something else I've never done. While trying out my new main jets yesterday (i.e. over 6000 rpm) the bike ran great and didn't stumble  but I think the clutch was slipping somewhat . I think I'll have another item to fix in the fall.

[kpier883]

Way ot go kpier.
I think my 550 is due for clutch work as well-something else I've never done. While trying out my new main jets yesterday (i.e. over 6000 rpm) the bike ran great and didn't stumble  but I think the clutch was slipping somewhat . I think I'll have another item to fix in the fall.

I encourage you to use a torque wrench on the spring cover casting.  Mine was really easy to break.  I got away with just springs - for 20 bucks that is a cheap thing to try before buying new plates...

Good luck.  How did the jets work, what size and where did you get them?

[TwoTired]

I think my 550 is due for clutch work as well-something else I've never done. While trying out my new main jets yesterday (i.e. over 6000 rpm) the bike ran great and didn't stumble  but I think the clutch was slipping somewhat . I think I'll have another item to fix in the fall.

I read somewhere on this site that these clutches sometime slip due to oil starvation.  (PJ, Hondaman?) Seems counter intuitive, but it has to do with oil swelling the fiber discs, and heavy springs squeezing the oil out.  My 76 550 slips some.  But, the more I ride it, the more it improves.  I speculate that frequently pulling in the clutch, allows more oil getting to the fiber discs.  When I take the bike out of storage next time, I'm going to pull the clutch in, tie wrap it the grip, and leave it over night.  If it works, it will be a pretty easy fix.  If not, well I do have a whole new Honda clutch pack to put in there.

Cheers,

[needswork]

How did the jets work, what size and where did you get them?

I have a 4 into 1 exhaust and individual filters. I bought 125 mains from the Honda dealer ($2 each). I was surprised how easy a job it was and how well it worked. 

Twotired: That's interesting. Please let me know if it works.