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CB500 clutch pushrods

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StPeter:
A common point of failure, I believe, and no longer available. I've just managed to get one from a guy in Milwaukee which was NOS.
There's a discussion on making your own http://www.sohc.co.uk/index.php/topic,3391.msg12852.html#msg12852 If you want to go down that route be aware that the actuator end starts life square and flat. The little dimple your old one is worn by the ball bearing. The end that bears on the clutch is radiused - I can't measure it but the rod diameter for the last 20mm is 7.5mm. I'd guess the radius on the end is 4-> 4.5 mm
The overall length is 255mm with a diameter of 8mm.
I can't imagine why Honda decided to make this a 3/4-piece construction with undercuts (or are then some sort of rolled retaining mechanism?). It looks desperately expensive to me!
Well those are the sizes; some hardening may be necessary depending what you chose to use to make it from.

Anyone got any bright ideas for getting the broken bit out without dismantling the clutch? I've tried a drop of loctite on the other bit . . . .

Bryanj:
Sorry mate, only way i ever found was taking the clutch outer pressure plate off!

As to the construction it is my belief that the original was made that way to make it lighter as the clutch seems to have a "Slow" action at the best of times and a heavier rod may make it worse---Having said that one of the last NOS ones i had, in a sealed numbered Honda bag, was a one piece steel rod, radiused on the one end and gold passivated.

z1100r:
Never seen one like that Bryan. I bought one 10 years ago and another beginning of last year both from DS and both the same - alum with steel ends in Honda bag with partnumber.The first new one lasted about 100miles..I figured out what was wrong after that, so decided to buy another new one last year whilst I still could. I used to put the original 500 engine back in every now and then when doing more tuning on the 600 - usually until I could stand the clutch no more , so not for long.

SteveD CB500K0:
I'm sure I saw that one of our sohc4.net cousins was manufacturing these (?)

StPeter:
Thanks for confirming my suspicions, Bryan! Oil change is probably a good idea. I can't see why an ally pushrod would make the clutch operation lighter than a steel one. There must have been a reason why they made such a performance about it. The one you describe sounds perfectly adequate.
I think I got lucky picking this one up! It's a loose chain that kills them, then?
I did a search on sohc4.net  but couldn't find anything under "clutch pushrod" or "clutch lifter" or even the part number.

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