Topic: Clutch problems.....oh boy....

[dylboss]

I'm sorry, I know this is not the right forum for this bike, but I'm desperate for some help, please! The "other bikes" forum is so quiet all the time.

So, I just replaced the handlebars on my '72 CL350, rewired everything through the bars, etc..  Well, when I went to put the clutch cable back on the lever, I heard this "pop" come from the cover area where the clutch cable enters the housing.  It seemed like I pulled the cable too far or something.  I screwed in the adjustment screw and cable to the lever, and now the clutch doesn't work.   The lever was very easy to pull back and forth, so I knew that the rod wasn't getting any pressure applied. 

So, I pulled off the cover and everything seems to be pulling back and forth normal, but the mechanism that is supposed to push in the rod seems to be slipping if the cable is adjusted too tightly.  Very strangely too, every 4th pull of the clutch, and it does that "pop", and I have to pull the cable off of the mechanism, let it seat all the way down, then push it up and reseat the cable on it.  This cycle happens over and over.

So I loosened the cable at the lower adjustment, and now the rod is getting pushed in, and the clutch feels normal now, but it is not disengaging.  I'm very confused.

Any help would be appreciated.

Thanks.

[VTCBike750]

My first suggestion....Take it apart and see whats in there. They arent too complicated. Do you have a manual?

[Trav-i]

Sounds like it's not adjusted properly, it sounds like it's pulling too far.  I would do a proper adjustment and go from there.  It backwards from a 750 just loosen all the adjustments bar and at the cover.  Then break the nut loose and turn the adjuster counterclockwise until you feel it touch, then back it off a quarter turn.  Then adjust the cable at the cover first (I think I took out almost all the slack there), then fine tune it at the lever.

If that doesn't work then you'll need to investigate further, including the rod and ball bearing and the cam mechanism.  They're pretty simple I'm sure you'll figure it out quickly.

Travis

[dylboss]

My first suggestion....Take it apart and see whats in there. They arent too complicated. Do you have a manual?

Thanks.  I did take it apart, well the cable/push rod mechanism.  Yes, I do have a manual.  What's strange to me is that it all worked before I removed the cable from the lever.  I rode it for 150 miles prior to that.  Just not sure what I'm missing here.  The bike has less than 8k miles, so i'm sure the clutch plates and others aren't worn out.

[dave500]

its the same set up as the cb500s i think?with the worm/corkscrew type adjuster on the left side?has the actuation arm become sloppy on that worm thread?or is the female part slipping in the housing?have you got a photo?

[VTCBike750]

Sounds like it's not adjusted properly, it sounds like it's pulling too far.  I would do a proper adjustment and go from there.  It backwards from a 750 just loosen all the adjustments bar and at the cover.  Then break the nut loose and turn the adjuster counterclockwise until you feel it touch, then back it off a quarter turn.  Then adjust the cable at the cover first (I think I took out almost all the slack there), then fine tune it at the lever.

I doubt the plates are worn out. If they are warped then it wouldnt of worked before. Definetly start with full adjustment of everything, starting at the clutch.

Great place to start!

[MoMo]

Seems like the ball bearing at the lower end is missing...Larry

[dylboss]

its the same set up as the cb500s i think?with the worm/corkscrew type adjuster on the left side?has the actuation arm become sloppy on that worm thread?or is the female part slipping in the housing?have you got a photo?

Yes, that's correct.  I'll try and get a photo tonight.  It seems that the female part is slipping when it is pulled to the top of the corkscrew.

Seems like the ball bearing at the lower end is missing...Larry

The ball bearing is there.

[dylboss]

So, I finally got a couple pics of this.  I've had both the cable tight and completely loose with no results.  Still cannot get the clutch to disengage, even though the lever feels normal.  Just doesn't make sense that it was working fine before I removed the cable.  Pull in the clutch at any length, and the thing just won't come out of gear.

[dave500]

are the ramps worn out where those three flying saucer landing gear balls ride up and cause the lateral action,is the long push rod broken?

[dylboss]

are the ramps worn out where those three flying saucer landing gear balls ride up and cause the lateral action,is the long push rod broken?

Doesn't appear to be worn out, and the rod isn't broken.  Like I said, it feels as though the rod is being pushed in when I pull the lever, but no clutch disengage.

[dave500]

have you riden this bike lately?is the clutch pack just stuck together,if you try and ride the bike to break the clutch free what happens once its hot?maybe time to remove the clutch cover if riding it dosent reveal anything?

[camelman]

I had the same issue with my CB350 twin.  You just adjusted the clutch incorrectly and over rotated the mechanism.  If you look at the two faces of the mechanism that mate up, then you'll see what over rotating will do.

Try going through the clutch procedure again regarding setting the big screw on the side cover.  If that doesn't work, then just set the big screw a little looser so that you don't get as much movement out of the clutch mechanism.

Also, check out the hondatwins.net forum.  Sprint66 knows his stuff!

[dylboss]

I had the same issue with my CB350 twin.  You just adjusted the clutch incorrectly and over rotated the mechanism.  If you look at the two faces of the mechanism that mate up, then you'll see what over rotating will do.

Try going through the clutch procedure again regarding setting the big screw on the side cover.  If that doesn't work, then just set the big screw a little looser so that you don't get as much movement out of the clutch mechanism.

Also, check out the hondatwins.net forum.  Sprint66 knows his stuff!

Yes, you hit this on the head!  That is exactly what is happening.  I've readjusted this thing like 4 times now, and I'm still having that same issue over and over again.  I did try and adjust the side screw closer with no success.  I don't know what else to do.  I guess I'll try and post on hondatwins.net.

[dylboss]

have you riden this bike lately?is the clutch pack just stuck together,if you try and ride the bike to break the clutch free what happens once its hot?maybe time to remove the clutch cover if riding it dosent reveal anything?

The bike has been ridden quite a lot lately, so I know it isn't anything with the clutch itself.  Was working flawlessy before I removed that blasted cable.  Now this overrotating thing is happening like camelman was explaining.

[mrrch]

I remember reading about the cable pop on the twins either on DTT or the Honda twins site.