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Post by gibbsy on Dec 8, 2007 13:29:13 GMT -5
HI
I am new here!
I have just bought an SR500 not my first I have owned 2 other SRs and 3 XTs previously and thought I knew everything I needed to about these machines.
But there is a problem with this one I could use a little help with as its had a real Mick Mc Spanners around it,
The guy who had it before me fitted new clutch plates and now the clutch doesnt work he also fitted 7 penny washers to the bottom end of the cable in a bid to try and make it work!
The problem I now have is I am not sure exactly what else hes done as the pushrods seem to short to work the clutch, so has anyone out there got an engine in bits who could tell me the exact length of both of the rods so I know where I am going with this, as I can see these havent been cut I am wondering if they are correct fot the bike.
There are 8 friction plates in there and I have measured them and they are the correct thickness and I cant think of any other reason the pushrods are about 6mm short of making the clutch work
ps I have taken the penny washers off!
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Post by bigshingle on Dec 8, 2007 15:00:32 GMT -5
I've got my '81, SR500H mostly apart. I didn't need to take both clutch push rods out, only the first. I don't have a micrometer, just calipers, but the first pushrod is 4 cm (1 18/32 inches) end to end. The engine is in an unheated garage in Minnesota and it's 5-degress F outside right now, so the second push rod is pretty tight in there (due to contraction.) I'm going to bring it in where it's warm later and will try to get it out — maybe with a magnet. (  ?) Could either or both of the rods be out of true? The manual calls for a .2mm bend limit. |
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Post by bigshingle on Dec 8, 2007 15:16:40 GMT -5
Another thought.
This may be hard to believe, but it happens fairly often apparently. (I've seen it mentioned on-line and heard about it at a bike shop recently.)
When you take off the cover there is a steel washer (6 mm thick?) on the kick-starter shaft. If this falls off the shaft while you are getting the clutch out, there's a good chance someone w/o experience may believe it came off the clutch shaft and put it there.
1) Do you have a machined steel washer (loose) on the starter shaft?
2) Do you have two washers and a conical lock washer on the clutch shaft?
If the the answer is "no" to #1 and "yes" to #2, then there's the problem. There should only be one washer, the lock-washer and the nut on the clutch shaft. The machined washer goes on the kick-starter shaft.
Just a thought.
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Post by canucksr on Dec 9, 2007 12:57:06 GMT -5
Maybe the clutch arm is out of adjustment. In front of the sprocket on the left-side there's an eccentric adjustment screw. If thats O.K., then there's got to be a spacer or washer out of place.
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Post by StewRoss on Dec 10, 2007 3:02:15 GMT -5
Hi, ...unless it's previous incorrect assembly...sounds like an adjustment issue to me as well. The screw eccentric adjusts the cam up or down and gives the clearance between the cam's ramp and the push rod end... SR  |
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Post by gibbsy on Dec 10, 2007 3:26:04 GMT -5
no its definately not an adjustment issue I know how to adjust these i.e line the lever up with the dot on the crankcase and then adjust the slack at the top end I know alot of people dont realise this.
When I install all of the plates and adjust it properly the pushrod will lightly touch the clutch centre cap and runs out of travel before it actually moves it, this is why the previous owner put penny washers on the bottom of the cable but obviously this throws the angle of the arm out of adjustment and gives a clutch thats to heavy to pull in
I dont think its a problem with the thrust bearings being in the wrong place as the gears on the back of the clutch basket run in line with the gear on the crank and the washer is present on the kickstart shaft as well.
The fact that the previous owner apparently only changed the clutch plates he probably wouldnt have removed the basket or centre
I am wondering if the owner before him shortened the length of one of the pushrods to get more wear out of the plates this is why I need to know the length of both rods
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Post by bigshingle on Dec 10, 2007 12:48:27 GMT -5
gibbsy, it looks like I'm going to have to get the second pushrod out and measure it.
I've turned the case on it's side, tapped, shaken and begged, but it won't be coaxed. The only magnet I have is too big to fit down the hole.
How do you get the second shaft out without taking everything apart?
Let me try some other things...be back in awhile.
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Post by bigshingle on Dec 10, 2007 13:32:22 GMT -5
Okay, all it needed was some warm coddling and the threat of putting it out in the snow to get it to cooperate.
It's 80 mm long.
Check to be sure the nut goes on the clutch shaft far enough to leave a small amount of shaft sticking out.
Hope this helps.
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Post by gibbsy on Dec 11, 2007 6:24:22 GMT -5
Thanks for your help big shingle I am going to measure my rods tonight and ill let you know the outcome thanks again for your help
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Post by gibbsy on Dec 17, 2007 16:17:45 GMT -5
Everything checks out correctly but for some reason the pushrods seem to short I am not the only person to have looked at this engine I have also had a couple of friends take a look (one of them a 45 year old apprenticeship served motorcycle mechanic) and weve all come to the conclusion that someone has had the motor right down and put a thrust washer in the wrong place but obviously I dont really want to pull the motor right down so weve stacked the plates in a different order and left one of the cork ones out, now I know this isnt the correct way of doing things but this is working perfectly with no slip or drag and no clunks and as I have owned 2 SR500s and 3 XT500s I know how they should feel!
It defies all the rules!!!!
Thanks for your help everyone
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armen
New Member
Posts: 3
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Post by armen on Dec 17, 2007 19:47:47 GMT -5
As wacky as it sounds, I've done 2 SRs that upon reassembly (new clutch), there wasn't enough adjustment to be had. I pulled the steel end off the pushrod, used a small nut as a spacer, and pressed the end back on. If I hadn't been the one to take the engine apart, I'd be looking for some lost piece.
Good luck!
-Armen
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Post by bigshingle on Dec 17, 2007 22:23:57 GMT -5
"The inexplicable cussedness of inanimate objects.." -- Eric Hiscock.
Glad you got it to work.
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