Honda CB500K1 clutch and gear shifter

 While rebuilding the engine it was a no brainer to also replace the worn gear shift spindle and check all other clutch parts. The gear shit spindle was stripped and they fixed it by grinding a groove in it and then hammering a metal pin in it while the gear change pedal was on the spindle. It works well but new is better.

Worn shift spindle Honda CB500K1

In order to remove the gear shift spindle you have to remove the clutch assembly (the basket that holds the clutch plates), after that you can just slide it out while holding down the gear shift arm which is part of the gear shift spindle.

Now you can easily replace the gear shift spindle oil seal on the other side.
The new gear shift spindle from CMSNL will fit but it has a slightly different design as you can see in the pics. So in order to fit it you have to take out the shift drum stopper bolt (right top of pic, just above the small spring) otherwise you can't get the gear shift arm in place.
Don't forget to replace the oil seal on the shift pedal side.

Shift spindle and shift drum stopper Honda CB500K1

Removing worn shift spindle Honda CB500K1

Worn (left) and new (right) shift spindle Honda CB500K1

 

Clutch basket Honda CB500 four 1972

 

New gear shift spindle and oil seal Honda CB500 four

I already bought new clutch friction disks and clutch springs but when I checked the disks they were in almost new condition. The standard value is 3.3mm thickness and these ones were over 3.2 mm.

Clutch plates and springs Honda CB500K1

Measuring friction disks Honda CB500K1

You also have to check the metal clutch plates for warp by putting them on a completely smooth surface like eg. a glass plate and check with a feeler gauge if it's still not wrapped.

The 4 clutch springs standard value is 31.9 mm and the ones on the bike measured 30.9 mm , still within the limit of 30.5 mm. When I measured the new springs they were way longer than the original ones, 36.2 mm. They're so called heavy duty springs but I'm not gonna use 'em because I'm afraid they could break/snap the aluminium mounting pins ...

Measuring clutch springs Honda CB500K1

Clutch specs Honda CB500K1

Another clutch part that needed attention was the clutch adjuster which is located in the left crankcase cover. It is pretty common for clutch adjusters to crumble at the top after many years of duty. This was also the case with this adjuster as you can see in the pics. Be carefull not to loose the metal ball that goes inside the clutch lifter and pushes on the clutch lifter rod when engaging the clutch.

Parts list left crankcase cover Honda CB500K1

Exploded view parts left crankcase cover Honda CB500K1

Broken clutch adjuster Honda CB500K1

Old and new clutch adjuster with oil seal Honda CB500K1

Worm that sits inside clutch adjuster Honda CB500K1

Old and new clutch adjuster with oil seal Honda CB500K1

Old and new clutch adjuster with oil seal Honda CB500K1

Luckily you can still buy new original Honda clutch adjusters and if you bought the complet gasket set for the Honda CB500K1 from 4into1.com it will also come with a new oil seal which goes on top of it to keep the grease in.

 

Inside left crankcase cover Honda CB500K1

Left crankcase cover Honda CB500K1

Clutch adjuster inside left cover Honda CB500K1