Motorcycle Repair: Honda CL-360 stuck clutch, clutch adjustment, clutch lever


Question
The clutch handle on my 1975 Honda CL-360 got stuck today, so that the clutch is disengaged.  I brought it home, and took off the sprocket cover, just behind the cover for the gearbox and transmission.  Whole clods of dirt came out, and I think that was keeping the spring from being able to retract the clutch cable.  But now, I'm having trouble getting it back together - I cleaned and repacked the bearings in the cylinder behind the clutch adjustment screw, but I can't get the sprocket cover back on without the spring pulling the cylinder askew.  Any advice would be appreciated.

Answer
Brian,

-the trick to this is backing off all your clutch adjustment
screws and even remove the cable from the clutch
lever.
-The point is to get enough slack so the cable will
allow the assembly to screw in far enough so the
case will go back on without pushing on the clutch
push rod.
-Once the case is on, you can
attach the cable and adjust the clutch screw
with the lock nut on the outside. Turn it in
until it gets tight and back it off a quarter turn,
lock the nut. Adjust the lever for 1/8-1/4"
free play.
-Don't forget the ball bearing (#10-5/16) between
the cylinder assy and the push rod in the engine
case. Might want to check the push rod in case
it's bent.