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Everything Dirt Bike
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Clutch Problem
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<blockquote data-quote="divemaster5734" data-source="post: 163340" data-attributes="member: 1320"><p>Been away a few months, hope everyone is doing well and getting ready to hit the dirt.</p><p>Got a problem with a project bike, hopefully someone here can help.</p><p></p><p></p><p>I picked up a pretty beat 85 CR 250.</p><p></p><p>It was evident there was owner neglect.</p><p></p><p>It had good compression.</p><p></p><p>Rebuilt the carb, and replaced probably 15 missing bolts that had vibrated out and never been replaced.</p><p></p><p>There wasn't even 1 bolt holding up the exhaust, just the 2 springs at the head, and the collars for the intermediate and muffler transitions.</p><p></p><p>The clutch wouldn't disengage the <a href="http://www.thumpertalk.com/topic/1075791-cr250-clutch/#" target="_blank">engine<img src="http://images.intellitxt.com/ast/adTypes/icon1.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a>, so ordered an ERB replacement.</p><p></p><p>When I took it apart there were springs and plates from a different <a href="http://www.thumpertalk.com/topic/1075791-cr250-clutch/#" target="_blank">model<img src="http://images.intellitxt.com/ast/adTypes/icon1.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a> installed.</p><p></p><p>Put in the right spec and still couldn't get it to engage.</p><p></p><p>Filed down the ridges on the basket and still nothing.</p><p></p><p>Got a replacement basket from eBay, and also noticed one set of roller bearings that go between the basket and crank shaft was missing, so replaced those too.</p><p></p><p>Went to <a href="http://www.thumpertalk.com/topic/1075791-cr250-clutch/#" target="_blank">Honda<img src="http://images.intellitxt.com/ast/adTypes/icon1.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a>, and got the factory spec gear oil.</p><p></p><p>There were some random bolts that stripped or broke during the process.</p><p></p><p>One in particular was one of the six that hold the clutch plates to the basket.</p><p></p><p>I had to tap a 7mm instead of the 6mm.</p><p></p><p>I know there's a little extra weight in the <a href="http://www.thumpertalk.com/topic/1075791-cr250-clutch/#" target="_blank">new<img src="http://images.intellitxt.com/ast/adTypes/icon1.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a> bolt, but just figured the entire mass of the rotating clutch assembly was more than enough to overcome any rotational imbalance by 1 or so gram weight difference in the bigger diameter bolt.</p><p></p><p>I had the new plates soaking in oil for weeks, waiting for broken or missing <a href="http://www.thumpertalk.com/topic/1075791-cr250-clutch/#" target="_blank">parts<img src="http://images.intellitxt.com/ast/adTypes/icon1.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a>.</p><p></p><p>I made sure the actuator rod, bearing, and end cap were good, even replaced the end cap that pushes against the inner clutch hub plate.</p><p></p><p>Just started it up and still no clutch.</p><p></p><p>Before putting on the side cover I checked the <a href="http://www.thumpertalk.com/topic/1075791-cr250-clutch/#" target="_blank">action<img src="http://images.intellitxt.com/ast/adTypes/icon1.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a>, and could see the inner hub push out, and saw a gap form between pates.</p><p></p><p>Pulling the clutch feels more like <a href="http://www.thumpertalk.com/topic/1075791-cr250-clutch/#" target="_blank">brake<img src="http://images.intellitxt.com/ast/adTypes/icon1.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a> action than clutch.</p><p></p><p>Once you have the initial resistance of the clutch pull on a normal <a href="http://www.thumpertalk.com/topic/1075791-cr250-clutch/#" target="_blank">bike<img src="http://images.intellitxt.com/ast/adTypes/icon1.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a>, it stays the same no matter how far you pull it in.</p><p></p><p>This has resistance that increases as you pull, and it's nearly impossible to pull it all the way in.</p><p></p><p>As I said, <a href="http://www.thumpertalk.com/topic/1075791-cr250-clutch/#" target="_blank">working<img src="http://images.intellitxt.com/ast/adTypes/icon1.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a> the lever action with the cover off I could see the housing move, and the pressure releases on the clutch plates.</p><p></p><p></p><p></p><p>I am stumped.</p><p></p><p></p><p></p><p>Any <a href="http://www.thumpertalk.com/topic/1075791-cr250-clutch/#" target="_blank">advice<img src="http://images.intellitxt.com/ast/adTypes/icon1.png" alt="" class="fr-fic fr-dii fr-draggable " style="" /></a> would be greatly appreciated.</p><p></p><p></p><p></p><p>Thanks in advance.</p></blockquote><p></p>
[QUOTE="divemaster5734, post: 163340, member: 1320"] Been away a few months, hope everyone is doing well and getting ready to hit the dirt. Got a problem with a project bike, hopefully someone here can help. I picked up a pretty beat 85 CR 250. It was evident there was owner neglect. It had good compression. Rebuilt the carb, and replaced probably 15 missing bolts that had vibrated out and never been replaced. There wasn't even 1 bolt holding up the exhaust, just the 2 springs at the head, and the collars for the intermediate and muffler transitions. The clutch wouldn't disengage the [URL='http://www.thumpertalk.com/topic/1075791-cr250-clutch/#']engine[IMG]http://images.intellitxt.com/ast/adTypes/icon1.png[/IMG][/URL], so ordered an ERB replacement. When I took it apart there were springs and plates from a different [URL='http://www.thumpertalk.com/topic/1075791-cr250-clutch/#']model[IMG]http://images.intellitxt.com/ast/adTypes/icon1.png[/IMG][/URL] installed. Put in the right spec and still couldn't get it to engage. Filed down the ridges on the basket and still nothing. Got a replacement basket from eBay, and also noticed one set of roller bearings that go between the basket and crank shaft was missing, so replaced those too. Went to [URL='http://www.thumpertalk.com/topic/1075791-cr250-clutch/#']Honda[IMG]http://images.intellitxt.com/ast/adTypes/icon1.png[/IMG][/URL], and got the factory spec gear oil. There were some random bolts that stripped or broke during the process. One in particular was one of the six that hold the clutch plates to the basket. I had to tap a 7mm instead of the 6mm. I know there's a little extra weight in the [URL='http://www.thumpertalk.com/topic/1075791-cr250-clutch/#']new[IMG]http://images.intellitxt.com/ast/adTypes/icon1.png[/IMG][/URL] bolt, but just figured the entire mass of the rotating clutch assembly was more than enough to overcome any rotational imbalance by 1 or so gram weight difference in the bigger diameter bolt. I had the new plates soaking in oil for weeks, waiting for broken or missing [URL='http://www.thumpertalk.com/topic/1075791-cr250-clutch/#']parts[IMG]http://images.intellitxt.com/ast/adTypes/icon1.png[/IMG][/URL]. I made sure the actuator rod, bearing, and end cap were good, even replaced the end cap that pushes against the inner clutch hub plate. Just started it up and still no clutch. Before putting on the side cover I checked the [URL='http://www.thumpertalk.com/topic/1075791-cr250-clutch/#']action[IMG]http://images.intellitxt.com/ast/adTypes/icon1.png[/IMG][/URL], and could see the inner hub push out, and saw a gap form between pates. Pulling the clutch feels more like [URL='http://www.thumpertalk.com/topic/1075791-cr250-clutch/#']brake[IMG]http://images.intellitxt.com/ast/adTypes/icon1.png[/IMG][/URL] action than clutch. Once you have the initial resistance of the clutch pull on a normal [URL='http://www.thumpertalk.com/topic/1075791-cr250-clutch/#']bike[IMG]http://images.intellitxt.com/ast/adTypes/icon1.png[/IMG][/URL], it stays the same no matter how far you pull it in. This has resistance that increases as you pull, and it's nearly impossible to pull it all the way in. As I said, [URL='http://www.thumpertalk.com/topic/1075791-cr250-clutch/#']working[IMG]http://images.intellitxt.com/ast/adTypes/icon1.png[/IMG][/URL] the lever action with the cover off I could see the housing move, and the pressure releases on the clutch plates. I am stumped. Any [URL='http://www.thumpertalk.com/topic/1075791-cr250-clutch/#']advice[IMG]http://images.intellitxt.com/ast/adTypes/icon1.png[/IMG][/URL] would be greatly appreciated. Thanks in advance. [/QUOTE]
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