Topic: CB550K0 Clutch Adjustment Issue

[TPIGroove]

Hello all. Following Hondaman's advice, I went into my clutch and swapped out the plates to get a stack closer to correct for my 550 (it originally had 7 plates at 0.107" thickness, which is too small). Mixing in some 750 plates (at 0.140") with the smaller ones is supposed to get me closer to the correct height and keep the clutch from slipping. The only issue I'm having is the lifter arm on the clutch housing cannot line up properly. The arm and lever are properly assembled inside the housing, but with the thicker stack it cannot reach the clutch until it's WAY up. This is the closest I can get it adjusted currently, turned fully inward. Turning it the other way simply raises the external arm further up, and the dot goes down. Does anyone have ANY clue why this is? I've searched all over and the only other clutch problems I've seen involve the arm being too low, with the dot way above the case's mark.

[flatlander]

are you sure the cam on the inside is in the right position? if it slips out from under the lever, the arm won't move fully.

[TPIGroove]

As I already stated, the lever assembly in the cover is properly assembled.

[flatlander]

well it's either the stack height or the cam. you also stated that the stack is correct height or close to it so let's assume that is the case.

then the only other possibility is that, if you turn the adjuster screw too far, the cam can slip out from under the inside lever. even if you assemble it properly this can happen when while you try to adjust it. it would lead to symptoms like you describe, with the outside arm seemingly being stuck.
this can easily be solved when taking off the cover with the bike lying on its left side so that the oil stays in.

[TPIGroove]

I've been through this plenty, the cam is not slipping.

[flatlander]

if you turn the adjuster screw too far to the right the cam can slip out. that's while the cover is installed.
as i said, the other option is that the stack hight is not correct, after all. i can only think of these two things that can cause this. for both you'd need to pull the cover.

[TPIGroove]

I understand what you're saying, but it's currently turned all the way to the left. I assumed it was the height, but hondaman insists that all 107 plates is too thin.

[flatlander]

the amount of free space in the clutch is really important as there is not much adjustment range for the lever, with the screw. it's only about 2mm. the clutch basket itself went through some modifications over the years which may affect how high you need to make the stack.

there are some pictures in this thread that may help:
http://forums.sohc4.net/index.php/topic,145565.msg1786260.html#msg1786260