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CA95 clutch upgrade

ballbearian

Veteran Member
Joined
Nov 22, 2021
Total Posts
8,108
Total likes
3,493
Location
Hagerstown MD USA
My chronic slipping clutch is (hopefully) a thing of the past. A couple of years ago a FB friend from Oz, who's done a lot on these Benly's told me about using the 175 racing clutch parts to beef up these, kind of wimpy clutches.
Basically by adding an exra set of friction disc and a steel, which is also an offset steel, not flat but dished, so that it lets the stack sit lower in the outer basket and the pressure plate stays even with the fingers of the basket.
Here is a pic with the new 5 disc set up installed and the old 4 disc unit on the floor.

zLxqVf4.jpg



The new racing kit contains thinner discs and a special 5th (or 6th if used in a 160/175) that has a reduced surface area to sit next to the offset steel. I don't use the new thicker springs, just the OEM. The overall stack height is almost the same due to the thinner discs.
Here is the ebay link for the kit
Honda CB160 175 Special Racing Clutch - Italian Moto3 supplier NewFren F1675A | eBay

Here is the part number for the offset steel (also on ebay) 22321-235-000 also 22321-302-000.

I'll update after a road test.
 
Thanks Tom, I'll try to make it a good one. Here is another pic showing the offset steel on the clutch inner, a modern aftermarket replacement friction disc and the special reduced surface area friction disc included in the Newfren racing kit that must sit next to the offset steel.

slgoC6a.jpg



Also, there are two washers (bushings, both 1.5mm), #12 washer B and #13 washer C, in the parts diagram. Only one will fit on the shaft, due to length (mine are CA95E-310.... and 406.... both '63). There are two different outers and inners listed for very early units (before CA95E-2100000), perhaps both are used there.
When using the offset steel the washer will be between the inner and outer, for clearance of that steel. It is not necessary to have a washer behind the outer and next to the primary shaft bearing, it is very close but I know it works because the 406 engine was run that way without any untoward wear, only very light contact from the large primary gear teeth on the crank bearing plate under it's gear (maybe I should add another pic). An un-splined washer was used also under the inner without problems.

It's raining still so I'm exploring some different options, plus the other project Benly will need a clutch. May as well strike while the iron is hot, as Grandpa used to say.
 
Here is a pic of the crank bearing plate that has lost just a bit of it's copper cladding from the primary gear teeth on the clutch outer. I removed the crank gear to see if there would be any drag when the clutch rotated and there really was none. I also wanted to verify that the oil pump plunger would not be affected and it was not, as there is so much side play in that.
So, relocating the 1.5mm thrust washer from behind the clutch to in between the inner and outer is not a problem. (picture taken of the other '63 project Benly motor)

FfrYQlG.jpg


Sun is coming, so time for a test ride and summary.
 
It works! 25 miles and no slip at all, even under heavy throttle fast shift uphill. No drag, found neutral even easier.

Summary:

option #1- Use offset steel, adds an extra friction disc. This is what I did.

option #2- requires a lathe, remove 1.6-2.0mm from back ledge of the clutch inner to add an extra flat steel and use the thinner 160/175 friction discs to add an extra friction also. This was my friend's suggestion, that he has done, but he didn't know about the offset steels.

option #3- only use 4 of the thinner 160/175 friction discs, which do have a wider surface area than the OEM, add an extra steel at the back to make up sufficient stack height. Maybe use the heavier wire gauge 160/175 springs or the NewFren racing springs.

So nice to be able to give this little bike the full beans. Over 60mph several times.
 
Excellent conclusion with options. Now a sticky thread for future help to others with the same situational need.
 
My chronic slipping clutch is (hopefully) a thing of the past. A couple of years ago a FB friend from Oz, who's done a lot on these Benly's told me about using the 175 racing clutch parts to beef up these, kind of wimpy clutches.
Basically by adding an exra set of friction disc and a steel, which is also an offset steel, not flat but dished, so that it lets the stack sit lower in the outer basket and the pressure plate stays even with the fingers of the basket.
Here is a pic with the new 5 disc set up installed and the old 4 disc unit on the floor.

zLxqVf4.jpg



The new racing kit contains thinner discs and a special 5th (or 6th if used in a 160/175) that has a reduced surface area to sit next to the offset steel. I don't use the new thicker springs, just the OEM. The overall stack height is almost the same due to the thinner discs.
Here is the ebay link for the kit
Honda CB160 175 Special Racing Clutch - Italian Moto3 supplier NewFren F1675A | eBay

Here is the part number for the offset steel (also on ebay) 22321-235-000 also 22321-302-000.

I'll update after a road test.
Hello! This is great news! Just to confirm, I need to order the kit in the first link and then both steel plates (22321-235-000 & 22321-302-000) referenced?
 
I have seen both part numbers for the offset steel. Option #3 above speaks to just using the wider surfaced discs, which seem to now be what the aftermarket standard replacement for CA95 is.
 
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