Honda-SOHC
SOHC.co.uk Forums => CB500/550 => Topic started by: DerekB on March 13, 2016, 06:51:34 PM
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I have a 1971 Honda CB500. I'm new to the rebuilding world, but I love tinkering in the garage. So I removed the LH crankcase cover to my bike the other day, no problems getting it off. But when I reinstalled it, the hand lever cable was not engaging the clutch to allow me to shift gears. I never adjusted anything inside the cover, but I didn't do something right when assembling. When I pull the lever everything seems to be working inside the cover. I did have several (maybe 6) small 1/4" orings that fell out of the cover, broken, when I removed it. I'm not sure where they go. My manual doesn't spec them out anywhere. Any ideas how I may have mis-assembled the cover?
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have you lost the ball bearing that fits in the operating mechanism, it bears against the pushrod.
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no the ball bearing is still in place. after installation, do I need to readjust something? does the pushrod slide in and out when squeezing the clutch handle?
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Thank you for all the excellent advice. Like I said previously, there were maybe 5-6 small broken o-rings that fell out of the cover when I removed it. Are these for the grooves that are on the push rod? Or somewhere else? I currently did not replace any of them since I was unaware of where they came from. My maintenance manual does not spec them out anywhere.
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Only O rings inside that cover are behind the oil pump and cannot fall out, also they are 15mm.
Sounds like somebody has put them in there to cover up a problem. As oddjob said check the ball bearing and pushrod, adjustment procedure is in the manual
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I disassembled the entire assembly today and gave it a good cleaning and new grease. Reassembled and adjustment and the clutch lever now works. The lever has always been fairly tight to squeeze and I figured out why when reassembling the parts. I don't think all the parts are stock inside the cover for the clutch actuation. I noticed that while squeezing the clutch lever, when the internal part is rotating it hits on the sheetmetal bracket inside making the clutch lever hard to compress. I didn't modify the bracket yet to give clearance, but its on the list now.
Thanks again to for the help!
Derek
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That sheet metal contraption is to stop excess damage if the chain breaks but can get bent and cause problems