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Old 03-17-2014, 02:41 PM
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Default cr125 clutch actuator arm lever disengaging? Help!!

     

Hello,
I just bought a 1987 cr125 and it runs awesome. The only problem is the guy thought the clutch cable was loose (which is was) and we fixed it for now but a new one is on the way. But there is a small piece (clutch actuator arm lever) that the cable attaches to and engages/disengages the clutch. This piece seems to slide out to the left (as in one of the pictures) and then it is loose and doesnt work the clutch, but if its pushed to the right again it hooks up. I am not sure why this keeps sliding out and there must be SOMETHING that should hold it in place and I dont know what it is?? There is a screw hole (in picture you can see the screw) and I put a flat screw in it and it seems to do a decent job but it eventually slides out again and the screw also makes it harder for me to pull the clutch. There must be some kind of easy fix to this and I would really appreciate some help!
Thanks,
Isaac



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Old 03-17-2014, 03:08 PM
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I'm not positive but I think you have too much slop in the cable. If the free play is set correctly, it should be enough free play but still "snug" in the notch.
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Old 03-17-2014, 03:10 PM
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had the same issue with my 97 cr250. i never really 100% fixed the problem but i noticed if you adjust your clutch cable tighter then it rarely happens. I kept a phillips head screwdriver wedged in my bar pad so i could just pop the clutch cover off and put it back in if it happend on the trails
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Old 03-17-2014, 03:29 PM
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I had the same idea and i tried that, but with the old "too long" cable on now ill have to wait until wednesday when the new correct one arrives and see if it fixes the problem.
Ill try that and keep you updated
Thanks,
-Isaac
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Old 03-17-2014, 03:46 PM
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I think the issue you are referring to is the clutch lifter popping out (to the left in the pictures) not the cable coming off of the lifter arm. If so, here's my input. The newer CRs have a piece attached to the stator that holds the clutch lifter in place, which is easily seen in the first few pictures of Dogger's 92-01 engine rebuild:
CR250 Engine Build Part 6

Your stator doesn't appear to have this feature, so I thought maybe the lifter has a slot machined in it and that screw is supposed to have a tip that engages to hold it in place. I looked at the microfiche (an easy to access tool that many people who post here either don't know how to use, or don't care to take the time to look at) hoping to see a special bolt that screws in to hold the lifter, but there isn't one. There is however, a part called "STOPPER, CLUTCH LIFTER" (number 13 in the microfiche) that appears to bolt in the right case under the flywheel to hold the lifter in place.
Take a look:
Save 20% on 1987 Honda CR125 OEM Crankcase 87-89 Parts | MotoSport

Unfortunately, it's no longer available from Honda. Maybe you can find one on Ebay or fashion something up from sheet metal or something to hold it in place. When the lifter slides out, the cam on the end no longer engages the lifter rod so the clutch doesn't work.
Oh, while you are at it, order a new flywheel nut. Looks like someone went to town with a chisel on yours.
JMV

Side note: If you are having problems with the clutch cable falling off, the cable is likely too loose. Either way, squeezing the little box that holds the cable will prevent the cable from being able to pop out the open slot there (hope that makes sense).
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Old 03-17-2014, 06:38 PM
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JMV
I think you're right and im going to look into it!
But no the cable is not coming off but it is loose, to fix the loose cable i used 2 nuts on top of the case to prevent the cable cover to enter the case, which basically just makes the wire shorter. (New cable on the way) but thank you very much
And to everyone else i tightened the tension on the cable and it didnt pop off after 10 minutes of riding or so. But ill see what that part is and keep it tight!
Thanks everyone! Ill keep you all updated
-Isaac

---------- Post added at 07:38 PM ---------- Previous post was at 05:46 PM ----------

So i found out i cannot buy the part i need except overseas (only 2 left) and its about $50 to ship it here and who knows how long..
Going to talk to the honda shop tomorrow and maybe fabricate some piece for now.
-Isaac
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Old 03-17-2014, 07:21 PM
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Good luck! Would be worthwhile to call some cycle salvage places and see if any of them have a 1987 CR125. Also cross reference that part number and see if it fits other bikes/ years to increase your chances of finding one.
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Old 03-17-2014, 08:01 PM
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I had the same problem years ago on a different bike. It wasn't fixed by cable adjustments. The design on the bike I had a light downward tilt to the actuator. So when it was pulled it would seat itself in there. Mine was warn out a little so it didn't have that tilt. I just made a small metal bracket that kept it pressed in there. I'm thinking it was my 97 RM250.
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Old 03-18-2014, 06:16 AM
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Definitely going to check some junk yards..
How would i cross reference the part number?
-Isaac
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Old 03-18-2014, 08:40 AM
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Usually I go to motosport.com and add whatever part you are trying to cross reference to your shopping cart. Then go to your shopping cart and click on the part and it will show all the different bikes it fits. In this case since the part is discontinued, you will have to just search through different year and model microfiches and see if it's in the fiche for the crankcase. Will take a bit of time, but that's part of owning an older bike you have to be wilng to spend some time researching things to keep it running.

Edit:
I normally don't like to do research like this for people because they need to be willing to do it on their own (kind of that give a man a fish feed him for a day teach a man to fish feed him fo a lifetime sort of thing). Anyhow, I was sitting here and decided to search through CR models. I only found that part (22821-KS6-700) on 87-89 CR125s. 84-86 use a different part and 90 must have switched to the newer design with it integrated into the stator. I didn't find it on any CR500s or 250s but I didn't search for very long.

Last edited by JMV; 03-18-2014 at 08:53 AM.
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