RestoCycle How-To: Install New Damper Rubbers in a 1979/1980 Honda CBX Clutch


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NobleHops
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RestoCycle How-To: Install New Damper Rubbers in a 1979/1980 Honda CBX Clutch

Post by NobleHops »

Here's another example of the damper rubber replacement, in a '79 Honda CBX clutch this time. The process for the '80 is identical, it just uses 9 damper rubbers, as opposed to the 6 shown here. The 81-82 Prolink CBX uses a spring-damped clutch basket, which is nearly silent: far superior to this and maintenance free in this respect, but you can still make a meaningful improvement to your 79 or 80 bike with this mod. As of this posting, there are a few places to get the parts: In the USA, KMCarburetor.com sells a kit with a superior screw that needs no fussing or filing after installation. In Europe 6Center.nl has the kits, using different screws, plus TheSupersportShed.com

Our patient! We'll add a short video of the problem in thread, but this is clutch basket from a 1979 Honda CBX that we are restoring. Beneath those 6 rivets there are teardrop-shaped damper rubbers, similar in function to what's used in the rear wheel sprocket cush drive. 40 years later those dampers are shrunken and rock-hard, and so there is play between the driven gear and the basket itself, causing clattery noise and vibration. Yes, "they all do that", but they don't have to! The 80 clutch basket is similar design, but uses 9 of the dampers. Same project.
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Step 1, we have to get this thing apart, non-destructively. We have done this in the past using a nice fresh 8mm drill bit and a sharp chisel and that works fine, but you are well advised to carefully centerpunch the soft rivet FIRST. If you get it well centered and use an 8mm drill, add a few drops of oil, and go slow, this is easily done by hand drill without a drill press or a fancy endmill.

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Repeat five more times and whack any remaining material off with a sharp chisel, and the steel plate lifts easily off. Now it's apart. That steel top plate that was held by the rivets captures the driven gear. The old hard rubber dampers were removed from those teardrop-shaped splines - they just slide right off, super loose and rock hard.
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Step Next is to drive those rivets out with a small punch:

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Not shown - 15 minutes with a 6mm x 1.0 spiral flute tap and some TapMagic. Once those rivets are out we have to tap the holes for the screws that we'll use to replace them. Tap all the way through, then blow out any swarf. Test fitting the screws here before assembly, good to go.
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Yeah, we vapor blasted it. It's aluminum, it wasn't bolted down, and it fit 🙂. That makes it easier to inspect and we did find some sharp edges on the basket fingers that we smoothed off. Otherwise it's good to go.
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Nils Menten
Tucson, Arizona, USA
'82 CBX, among others.
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NobleHops
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Re: RestoCycle How-To: Install New Damper Rubbers in a 1979/1980 Honda CBX Clutch

Post by NobleHops »

Those rubber donuts to the lower right are the new damper rubber parts, plus the shallow-head socket head cap screws that make up the kit, along with good installation instructions. Note the locktite too, you need that on these screws, because if they back out it could get Expensive in there.
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All together now! May as well torque those evenly, in a star pattern, at 108 inch/pounds. Why not. These are the screw heads you'll find in the kit from 6Center.nl, and they are a skosh over 3mm as they sit - The directions for the kit specify to mill or file those down to a height of 1.7mm to ensure proper clearance between the back of the basket and the shield inside the clutch housing. If you do not do this they will contact the shield and make a sound like castanets that will drive you insane till you figure out that it is this. No, I did not neglect this, but another bike we restored had that issue.
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Step last, we need to skinny these screw heads down to a max height of 1.7mm. We got all jiggy with the end mill, but that wasn't so effective, and so eventually we just grabbed a nice sharp flat file and went to town for 15 minutes, doing two at a time, measuring as we went. Done and done, and ready for installation.
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The screws furnished by kmcarburetor.com are much lower profile and do NOT need any filing or milling after installation.


Belt AND suspenders. Take a pin punch and stake these screws in with a smart rap on the soft aluminum just alongside the screw threads.
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Almost done. We lightly dry-blasted the clutch steels then checked them for warpage on a flat block with feeler gauges - good to go. The fibers were as usual in fine shape, they were having a soak in motor oil while we refurbished this basket. Be careful to get the steels installed with the sharper edge DOWN in this orientation, and with the grooves on the fibers in the proper orientation as shown in the manual.

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Nils Menten
Tucson, Arizona, USA
'82 CBX, among others.
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NobleHops
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Joined: Mon Jan 25, 2010 7:17 am
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Re: RestoCycle How-To: Install New Damper Rubbers in a 1979/1980 Honda CBX Clutch

Post by NobleHops »

And done!
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Nils Menten
Tucson, Arizona, USA
'82 CBX, among others.
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