• Husqvarna Motorcycles Made In Sweden - About 1988 and older

  • Hi everyone,

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Clutch pushrod length, 84 XC500

luckypabst

luckypabst

Husqvarna
I'm looking for a measurement along the length of the clutch pushrod for one of these big bore bikes. It seems as if my pushrod is too short... and the diagram I have doesn't show anything between the rod and throwout bearing (as some bikes have a ball bearing in here somewhere).

Thanks
Chris
 
on the clutch end is a 3 piece throwout bearing on the other end is a cam
pull your clutch cover and confirm 3 pieces, if all is well pull you clutch lever cam and look for excessive wear, if all is well look at your adjuster in the clutch cover, fyi the rod should have radiused ends, if the clutch was ever too tight one or all of these might be worn,
did you try running your clutch adjuster all the way in?
 
Everything is there and in serviceable condition. The clutch adjuster screw will thread in to below the edge of the throwout bearing before contacting the pushrod so that there's nothing left for the locknut to thread on to. I suppose the adjuster screw could have been swapped for something a little shorter at some point in time...

A quick trip through ebay shows that my pushrod is different than what's offered for sale for the 500. Mine has the diameter reduced by 1mm for a length of 17mm at one end. What I see on ebay has a consistent diameter for the entire length.

Judging by some hack-mods done by a previous owner, I'd say that this had been a problem for some time, so who knows what was done to the bike in the past.

Chris
 
just measured the one from my 82 cr 500

187 mm
the end that fits in the throw out bearing is slimmer then the rest of the shaft but prolly not 1 a whole mm

maybe someone lost the adjuster screw and replaced it with a off the shelf grub screw
 
Thank you much. Mine measures out at just shy of 185 mm... I don't think that 2mm is the problem so I'll play around with it some more today to see what i can come up with.

Chris
 
I had this engine down to each individual piece. No problem with the throwout cam.

I ended up adding material to the pushrod and turning it to the 187mm length as silverstreakNZ measured. Clutch pushrod adjustment is nicely in range now. Next up is getting the cable adjusted using a Japanese lever set...

Thank you guys for the suggestions!
Chris
 
It is a good upgrade to replace the pushrod and the actuating cam (the bit the operating arm and cable attach to) with the later type that has a cam profile on the actuator and a flat ended pushrod. The rounded point of the old style pushrod wears a nice little dimple in the flat actuator and this does not help for a smooth clutch action...
Andy Elliott.
 
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