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Old 10-17-2016, 11:39 PM
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Default 1997 CR250 Rebuild - Clutch Won't Disengage

     

Hey guys. I've already went through the search here and google but can't seem to find a good solution. I went through a complete top and bottom end rebuild on a '97 and I'm finding my clutch won't disengage in any gear.

The bike did run fine before the rebuild. Clutch disengaged as normal. Clutches used are the ones before the rebuild.

Here are the symptoms
- the clutch cable has no effect even at it's tightest or loosest
- the clutch bell does move out when the clutch is pulled in
- bike instantly dies in any gear other than neutral
- I cannot move the inner clutch basket after I tighten down the nut. This is without any clutches in the basket (normal not normal?)
- I can move the inner clutch basket when the nut is not tightened
- Nut is tightened to spec (59 ft lbs)
- plates/clutches are facing the correct way

Things I've changed:
- Seals, bearings, crank, cylinder, etc
- 80w Honda oil
- Steel clutch plates instead of aluminum (maybe this is an issue?)
- reused old clutches

I've double checked to make sure I wasn't missing any parts in the clutch assembly. My understanding is that the clutch basket should move freely in all gears but this doesn't seem to be the case when the nut is tightened down. As per the manual I have the clutch collar in, then the roller bearing, outer clutch, thrust washer, basket, thrust washer, lock washer, nut, clutch lifter assembly, plates & clutches, bell and springs. So assuming I'm not missing pieces, what could be going wrong?
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Old 10-18-2016, 08:23 AM
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There may have been a washer not put back in place between the clutch parts. There is one between the basket and the inner hub and one behind the basket.

Paw Paw
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Old 10-18-2016, 08:32 AM
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Quote:
Originally Posted by PawPaw View Post
There may have been a washer not put back in place between the clutch parts. There is one between the basket and the inner hub and one behind the basket.

Paw Paw
My thoughts as well.
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Old 10-18-2016, 11:33 AM
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Quote:
Originally Posted by PawPaw View Post
There may have been a washer not put back in place between the clutch parts. There is one between the basket and the inner hub and one behind the basket.

Paw Paw
I got the one behind the basket (large thick washer) but are you talking about 5 in this picture? I've got that also.

cdn.partzilla.com/diagram/honda/hom/b3c2bc14cda4a6a66a9f26a83c1e550a6bb52cd8.png (Link to picture because my post count is so low)

Thanks for the help so far
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Old 10-18-2016, 01:25 PM
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Quote:
Originally Posted by 3kneesdown View Post
- I cannot move the inner clutch basket after I tighten down the nut. This is without any clutches in the basket (normal not normal?)
no this is no normal should turn freely, also steel plates have nothing to do with this.

they are probably talking about the No17 thrust washer, if that is missing then the inner binds to the outer probably but i think you said that you've use that properly so it might be something else, maybe you installed the two thrust washers the other way around?
check for clearance issues by tightening the nut by hand slowly and turning the inner basket to see if it binds with the outer clutch basket.
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Old 10-18-2016, 01:48 PM
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Quote:
Originally Posted by byronk View Post
no this is no normal should turn freely, also steel plates have nothing to do with this.

they are probably talking about the No17 thrust washer, if that is missing then the inner binds to the outer probably but i think you said that you've use that properly so it might be something else, maybe you installed the two thrust washers the other way around?
check for clearance issues by tightening the nut by hand slowly and turning the inner basket to see if it binds with the outer clutch basket.
So I went back and messed with it. There definitely is clearance issues. I for sure have washers 17,18 and 19 in the correct place. Somehow the inner bell is binding with the outer bell. This is weird because the bells showed no issue prior to the rebuild. Maybe something is missing in on the main shaft transmission side? It's not loose and the gears shift fine...
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Old 10-18-2016, 03:25 PM
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I had an issue with a CR500 where the gear that is pressed into the center of the clutch basket had moved around ~1/32" or so. When I tightened the center nut it locked up as you are describing. I just threw it in my press, pushed it back in the problem solved. Worth a look.
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Old 10-18-2016, 04:10 PM
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2 other possibilities.....
1. Was the nut over tightened? If so it may have crushed the bearing just enough to allow for lock up.
2. If the basket is not totally seating in both the idler gears it will lock up when the nut is tightened.

Paw Paw
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