Cx500 Rick's stator wiring question.

[AlphaDogChoppers]

part number 20

http://www.hondapartshouse.com/oemparts/a/hon/506f7e83f8700229747b8868/shift-drum-shift-fork

I am working on a CX500 right now, and this particular area has given me nightmares. When the bike came to me, washer #20 was not there, and the narrow shoulder of the shift shaft was in fact digging into the aluminum case. I made a washer by boring out a 1/4" stainless fender washer, which made the teeth of the shifter shaft and gearshift arm line up nicely. I had the engine all assembled and in the frame before I discovered that the shift shaft was binding. So I had to pull the engine again. The odd thing was that even without the washer that I made, (approx 0.030" thick,) the shift shaft was binding. I machined some material from the shift shaft boss inside the case to give it a little endplay. Then I was able to discover that the shift arm was also binding. The only explanation that I could come up with for this happening is that the gasket for the rear case must be thinner than the OEM gasket. Anyway, I machined a little material off of the boss in the case where the shift arm seats in order to provide clearance so that the shift arm could move without binding.

Have you ever encountered something like this before?

Check out some of the pictures of my progress.
http://alphadogcustoms.com/BuildBlogs/cx500/

 

[rcmx5]

I am working on a CX500 right now, and this particular area has given me nightmares. When the bike came to me, washer #20 was not there, and the narrow shoulder of the shift shaft was in fact digging into the aluminum case. I made a washer by boring out a 1/4" stainless fender washer, which made the teeth of the shifter shaft and gearshift arm line up nicely. I had the engine all assembled and in the frame before I discovered that the shift shaft was binding. So I had to pull the engine again. The odd thing was that even without the washer that I made, (approx 0.030" thick,) the shift shaft was binding. I machined some material from the shift shaft boss inside the case to give it a little endplay. Then I was able to discover that the shift arm was also binding. The only explanation that I could come up with for this happening is that the gasket for the rear case must be thinner than the OEM gasket. Anyway, I machined a little material off of the boss in the case where the shift arm seats in order to provide clearance so that the shift arm could move without binding.

Have you ever encountered something like this before?

Check out some of the pictures of my progress.
http://alphadogcustoms.com/BuildBlogs/cx500/

I made my own washer and had the same problem, but I was able to locate a factory washer. I haven't had a chance to put it in yet due to the bike being at the upholstery shop, but from what you're saying I think I might just order an OE rear cover gasket as well.

 

[ParkdaleDan]

If your having trouble finding parts for your CX500, check out the CX500Forum.com They are good guys and answer fast!

 

[AlphaDogChoppers]

I made my own washer and had the same problem, but I was able to locate a factory washer.

My shift arm was binding even when I removed the washer that I made, and without the washer, the shift shaft teeth barely engaged the teeth on the shift arm.

The OEM gasket is pretty expensive, but probably worth spending the money on rather than the gasket from an aftermarket gasket set like I used. Fortunately, I coated both sides of the gasket with teflon paste, so the gasket did not bond to the cases and is reusable for the multiple times I have had to disassemble and reassemble the rear case.

 

[cxman]

the minimum gasket thickness compressed must be 8-10 thou

or it will bind up the shifter so its one place i always use oem