cr500 clutch mod/ hard lever pull

[FloridaRiderSG]

Its got a Moose basket.....never heard of that being an issue.

No steel washer, where exactly are you talking about.

Shaft= 9"

[4WHLr]

It would be in the center of the pressure plate where that stuff would push on it to release it.  The oil will sometimes hold it in there, when they get disassembled.
It looks like it might be there but its a liitle hard to tell.
 Just trying to make sure you dont have mismatched parts, since it was assembled incorrectly for some reason when you got it.

[4WHLr]

I have a new in the package Honda 89 update kit here that has all the 1989  clutch throw out parts in it, and the pushrod is maybe a tiny bit over 8"
 (Its still in the packaging)

[FloridaRiderSG]

ok thanks, mine is 8" also, miss typed.

What could have been done to make the pressure plate thrust washer create to much space in my clutch pack?

[4WHLr]

Are you still using the fibers and steels that you got it with?
Double check your thicknesses, and fiber (7), and plate count (6) with the honda manual.
Also double check that actuator arm is letting the rod return as far as it can.
When you have the push rod pulled out and the cable disconnected you can lift that arm up and out and have a look at the rod pocket also while you are there.
I think you said it has the big thrust washer is behind the inner clutch hub, right? #19 on a parts diagram

Check those and let us know, I'm running out of ideas lol

[FloridaRiderSG]

OK thanks going to try that today. Has to either be the fibers are worn or something with the shaft/rod.........theres not to many other things. I appreciate your help.....thanks. Ill post up later tonight what I find out have a few appointments today.

I have seven fibers and 6 plates, one of which is 400ex , its .50 thicker then the 250r's so that should have made the pack tighter.

[FloridaRiderSG]

Does anyone know the difference in clutch fibers? Im just going to put in new ones.

DISK, CLUTCH FRICTION
22201-KA3-712  In Stock

6DISK, CLUTCH FRICTION
22201-KAE-000  In Stock

[FloridaRiderSG]

So its got to be the shaft or the actuator. Is the vertical shaft that the cable attaches to should that have play in it? It moves almost a quarter inch back forth.

[evaneyeball]

I don't know if this helps at all, I do know this is random but while I was rebuilding my motor I realized that a short, valve pushrod from a 78 454 Chevy is the exact same length and slightly bigger around as a 250r clutch pushrod. Very random but if anyone else needs a reacement as long as they aren't bent they'll work. And generally made if better material I think

[FloridaRiderSG]

OK got ti, it ended up being the clutch lever arm. I only used one thrust washer at the pressure plate, the 400ex spacer and the cr500 springs, it works great and the lever pulls WAY easier. Thanks for the help guys, appreciated.