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CR250 Clutch

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I picked up a pretty beat 85 CR 250.

It was evident there was owner neglect.

It had good comression.

Rebuilt the carb, and replaced probably 15 bolts that had vibrated out and never been replaced.

There wasn't even 1 bolt holding up the exhaust, just the 2 springs, and the collars for the intermediate and muffler transitions.

The clutch woudn't disengauge the engine, so ordered an ERB replacement.

When I took it apart there were springs and plates from a different model installed.

Put in the right spec and still couldn't get it to engauge.

Filed down the ridges on the basket and still nada.

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 Honda, 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 new 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 parts.

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 action, and could see the inner hub push out, and saw a gap form between pates.

Pulling the clutch feels more like  brake action than clutch.

Once you have the initial resistance of the clutch pull on a normal bike, 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, working 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 advice would be greatly appreciated.

 

Thanks in advance.

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Just posted this in the bike specific topics, but then didn't see it in the new posts, so reposted it here.

My apologizes for double dipping, I've only made a couple posts and am obviously unfamiliar with the procedure.

 

 

I picked up a pretty beat 85 CR 250.

It was evident there was owner neglect.

It had good comression.

Rebuilt the carb, and replaced probably 15 bolts that had vibrated out and never been replaced.

There wasn't even 1 bolt holding up the exhaust, just the 2 springs, and the collars for the intermediate and muffler transitions.

The clutch woudn't disengauge the engineicon1.png, so ordered an ERB replacement.

When I took it apart there were springs and plates from a different modelicon1.png installed.

Put in the right spec and still couldn't get it to engauge.

Filed down the ridges on the basket and still nada.

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 Hondaicon1.png, 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 newicon1.png 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 partsicon1.png.

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 actionicon1.png, and could see the inner hub push out, and saw a gap form between pates.

Pulling the clutch feels more like  brakeicon1.png action than clutch.

Once you have the initial resistance of the clutch pull on a normal bikeicon1.png, 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, workingicon1.png 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 adviceicon1.png would be greatly appreciated.

 

Thanks in advance.

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