Motorcycle Repair: 1976 CB550K - Stiff clutch, honda cb500, clutch springs

Question
Hi Bill,

wonder if you can help; the clutch on my wife's 550 is incredibly stiff. I've worked lubricant through the sleeve and disconnected the cable from the clutch itself and so know the cable itself is not the problem.  Can you advise what may be causing this and how to remedy it?

Thanks,

Rob

Answer
Rob, if your bike is the early series, based on the CB500K, then it should have the clutch release mechanism shown here:

http://www.cmsnl.com/honda-cb500-500-four-k2-usa_model461/partslist/E++11.html

#5 is the clutch adjuster and it is made from a soft material that wears out, especially when it isn't kept well-lubricated.

I would check the condition of both #3 and #5, but usually the adjuster is the part that has worn threads. This part dates to the 250-305 series bikes of the 1960s, but should still be available from Honda. Pack it full of high temp grease before assembling it into the cover.

If your cable is in good shape, then replace the worn parts, loosen all clutch cable adjusters, then turn the clutch adjuster piece until it stops, then back of ever so slightly. Adjust the cable slack at the bottom cable adjuster, then fine-tune at the handlebar adjuster. If the clutch springs haven't been swapped for "heavy-duty" parts or there isn't excessive wear in the clutch basket/hub splines, the clutch should resume normal feel/operation again.

Honda updated the whole release mechanism for the 1977-78 models to something more modern and less prone to wear.

Bill Silver