gearbox

is there a manual clutch conversion for a cf70 chaly

The easiest thing to do while keeping to Honda parts is to use either a 4-speed or 5-speed gearbox from an SS50 and then fit your head, barrel & piston and a clutch lever to the LH handlebar. The 5-speed engines fetch better money than the 4-speed but of course give you more flexability.

The manual clutch conversion has little to do with the gearbox.
It's even possible to convert a 2-speed into manual clutch.
It's the same way of working and you need the same parts.
I have a complete manual (with pictures) somewhere laying around.
I can post it next week if you like. (off snowboarding this week!)

It's less work as the whole top end swap.
If you choose to get a second hand bottom engine with manual clutch, keep in mind that
- you'll have to replace the clutch plates soon enough (which is almost the same amount of work as fitting the complete clutch)
- the 5 gear boxes are not highly recommended if you're looking to tune the engine. Fitting of a reinforced first and second gear is highly recommended.

Conversion kits are widely available:
Kitaco, Takegawa, TB, DRP and of course Honda.

Is the manual clutch conversion a case of replacing the clutch cover & assembly?
My reply was aimed at a straight unit swop (i.e. remove one engine / gearbox assembly and replace with another of known quality) rather than working on the original unit, the swop can be completed very quickly even if you decide to changeover the original top end rather than using a separate set. This is something my dad did to his ST70 back in the 1970's and the additional gears made the bike much easier to ride especially when 2-up, my brother (who now owns the bike) only re-fitted the original 3-speed auto engine a couple of years ago to put it back to original.
Never had a problem with the 5-speed gearboxes. I ran one on my track bike when I was at school in the 70's, my SS50 was a 5-speed (still owned by my brother and at the last count it had covered about 60K miles on the original gearbox) and my brother also owns several other 4 & 5-speed SS50's and I can't recall a single issue of gearbox failure. I did replace the clutch plates on my 5-speed once but that was after a very significant milage had been covered.

LITCH wrote:Is the manual clutch conversion a case of replacing the clutch cover & assembly?

Yeah, it is. Not that much of wwork, really.
When mounted in a stock engine (full 72cc or less) the gearbox is indeed strong enough.
Only when highly tuning the engine (106cc +), the first gears of the 5-speeder are quite fragile.

Waynus,

Do you still have that manual kicking about?

I want to convert one of my bikes to manual, I think I have all the parts apart from the gear selector which I believe is different?
Certain I read somewhere that you can cut the automatic selector down so it can be used in a manual set up.

Any advise welcome,

cheers,

Blue

Sorry man, can't seem to find it.
I know it should be available on the web as well, I belive on a German website.

You can still use the original semi gear lever - if you operate it gently.