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500 clutch adjustment

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deltarider:

--- Quote from: Bryanj on July 31, 2025, 12:25:14 PM ---Not sure about Deltas instructions as i always found you needed as much movement on the arm as possible

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A shorter way to arrive at a proper adjustment, might be possible by just trial and error. ;)
BTW, Honda was not consistent in depicting the position of the locknut where the cable enters the cover. I have seen pics where it sat near the adjusting hexagon, other pics showed it down near the cover and even a pic where it was halfway, letting us wonder: where is it supposed to be?

Bryanj:
I found that the best way was to turn the big alloy bit with a flat bar till no free play then move it to give a small amount of play, then take up most of cable play at sprocket cover but not all to leave easy adjustment at the bars

NOTE:-

There is a bulletin inAsh's dropbox where the modified later alloy screw part has a "notch" at one end of the slot which must be in a certain range

deltarider:

--- Quote from: Bryanj on July 31, 2025, 06:53:11 PM ---I found that the best way was to turn the big alloy bit with a flat bar till no free play then move it to give a small amount of play, then take up most of cable play at sprocket cover but not all to leave easy adjustment at the bars
[...]

--- End quote ---
That's the procedure in the Owner's Manual and the Shop Manual. I have the feeling this procedure presumes a brand new clutch cable. I applied this working order last year having a clutch cable which has done over 60.000km. So I had zeroed the cable so to speak as if it was a new one and I ended up with a very stiff clutch, I can tell you. Now my cable, although it still slides as new, has stretched ofcourse. So I studied what actually goes on and I have managed to have a much lighter operation now by first compensating the cable for its wear by its hexagon adjuster and then position the big screw.
As mentioned before Honda was not consistent in depicting the position of the locknut where the cable enters the cover. I have seen pics where it sat near the adjusting hexagon, other pics showed it down near the cover and even a pic where it was halfway. Where would you suggest to have it?

deltarider:

--- Quote from: deltarider on July 31, 2025, 09:42:07 PM ---[...]
As mentioned before Honda was not consistent in depicting the position of the locknut where the cable enters the cover. I have seen pics where it sat near the adjusting hexagon, other pics showed it down near the cover and even a pic where it was halfway. Where would you suggest to have it?

--- End quote ---
It seems nobody has the answer.

florence:
As a regular 500 rider, I have always found, like Bryan, that the best way is to take up all the slack against the pushrod with the slotted screw and then back off about 1/8th-1/4 turn, then deal with the cable slack via the cable adjuster.  Seems to work fine every time for me.

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