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Discussion Starter #1
I picked up a salvage motor for my project bike. I'm a bit put off by the way the shifter action is. The linkage is moveable left to right about an inch or so. It doesn't ratchet into gear either. (I don't feel it "clunk" and the drive sprocket spins regardless of up or down movement) I pulled the side cover off and you can see the shift shaft rotate freely to hit the case one direction and it disappears behind the clutch assembly the other way.

I haven't got to pull the clutch assembly off the shaft yet. (It's 30ish degrees in the garage atm.)
My question is what to look for when I get the hub assembly off.

(Yes I'm looking into finding a decent shop manual too)

cheers.
 

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The linkage is moveable left to right about an inch or so.
You mean the shaft that has the splines on the end that comes out of the left side of the engine?

If so, inside the motor under the clutch, it has a thin metal piece bolted over it to keep it from pushing in. It is thin and has probably bent. You might have lost a few little pieces so you will have to take the clutch off to put it back together. It's not too bad though.
 

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Discussion Starter #4
You mean the shaft that has the splines on the end that comes out of the left side of the engine?

If so, inside the motor under the clutch, it has a thin metal piece bolted over it to keep it from pushing in. It is thin and has probably bent. You might have lost a few little pieces so you will have to take the clutch off to put it back together. It's not too bad though.
Any ideas how to get the "crushnut" off the end of the shaft? I pryed all I could back out of the grove and cannot figure how to hold the basket in place so I can back the nut off.


On a side note: I'm finding a few missing pieces too... not a good way to begin I'm thinking.
 

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if you have an inpact gun, put the clutch plates and discs back in and impact it off.

That tab on the locknut is pretty thin and what is still left in the groove after you pried out as much as you could will not cause any damage. Also, the threads on the end of that shaft are heat treated and the nut is soft so the threads will cut into the nut before the nut cuts into the threads.

If no impact, Honda makes a tool to hold the clutch while installing and removing that nut. Pretty penny for that tool I'd imagine. I went against the manual and just did both with the impact even though it calls out for a specific torque on the nut before pinning it in place. I have 3K miles since and no problems.

put the clutch plates in before impacting just to keep the shaft from rotating at a high RPM. The plates will offer a little friction.
 

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Discussion Starter #7
Ok, I'm lost. The nut I need to loosen is located "behind" the clutchplates. ie: You have to loosen the six bolts and remove those bolts/springs and the outer end of the clutch hub assembly to get to the nut that holds the rest of the clutchbasket on the shaft...

It's behind all that mess that the shiftlinkage I need a look at lies.
 

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Yes. Take the pressure plate off. The piece that the 6 springs hold in. then the nut is behind there.

I was saying don't take out you clutch plates and discs. Those are the seven fiber plates and 6 steel discs. The onlt reason for that is when you put an impact on the nut, the shaft will spin freely without the plates and discs and you will not get the nut off. Leaving the plates and discs on will give the shaft enough resistance that it won't spin as fast as the impact and the nut will comes off.

You can do it other ways. put a rag on the clutch basket and hold it with your hand while you impact it, but if something goes wrong, that could be painful.
 

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Discussion Starter #9


I'm still lost. I don't see how you can keep the discs in place without the plate there to hold em in...Mind you I'm not trying to be difficult here. Somehow I just can't get my mind to grasp. I'll blame the impending wedding. heh. Be back around the first and let you know how it goes. Thanks for taking the time to help.
 

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The plates and discs are oily. Easy to slide apart but not so easy to just pull straight apart. When they're in the basket, they'd have to pull straight apart. They won't fall out.
 

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Discussion Starter #11
I "engineered" my own little adapter to hold the housing in place. Upon removing the hub assembly and the large gear behind it, I found the problem with the shift linkage. There's a tab that keeps the linkage from moving, broken....

Then I noticed the poorjob someone did of patching a broken engine casing...*sigh*

I believe I am going to look for another powerplant.
 
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