CRF450R '07 model has cracked the left crankcase from the clutch pivot arm all the way across the top of the main bearing. Is this a common problem? Honda had 3 left cases in stock!! The bike is used for Motard racing and has had quite a few engine mods done. Cheers.

FOLLOW THIS STEPS AND FIX IT. God bless you Lubrication

1

Detach the ends of the pedals from the crank axles. Spread a layer of machine grease over the crank axles, then reattach the ends of the pedals.

2

Remove the bolts connecting the pedals to the swing arms. Detach the pedals from the arms, then spread a layer of machine grease over the axles on the swing arms. On some models, the bolts may also serve as the axles. Reattach the pedals to the arms.

3

Remove the bolts connecting the swing arms to the elliptical's upright. Detach the swing arms from the upright, then spread a layer of machine grease over the axles on the upright. Reattach the arms to the upright.

Link Arms

1

Unplug the power cord. Identify the pivot points where the lower handlebars and the footpad link arms connect at each side of the machine. Use a screwdriver to remove the inside and outside elbow covers at each connection. This will expose the pivots.

2

Put a box wrench on the lock nut at the inside of one pivot and loosen the bolt with an Allen wrench. Remove the bolt and check the assembly for nylon spacers or a bearing. If no spacer is found, proceed to the next step. Replace the nylon spacers, reassemble the connection and reattach the elbow covers. Repeat this at the opposite side of the machine.

3

Have an assistant hold a deep socket against the inside face of the pivot hub. Make sure the socket is large enough to allow the bearing to pop out. Insert the point of a flat screwdriver into the outside of the hub until it contacts the bearing. Tap the handle of the screwdriver with a hammer to remove the bearing. Repeat this to remove the bearing on the opposite side.

4

Hold each bearing next to one ear and turn the inner race with your finger. If you hear grinding noises or the bearing is rough, it must be replaced. Lubricate the bearing with lithium grease and a grease gun. Replace the bearing into the hub. Reattach the lower handlebars and footpad link arms and put the elbow covers on.
Pedal Arms

1

Use a flat screwdriver to unseat the tabs that hold the front top cover in place. This will expose the flywheel and pedal arm connection points. Rotate the flywheel by hand and determine whether lubrication will accomplish the repairs. If the bearings are exposed, use a grease gun with an extension nozzle and lubricate both bearings with lithium grease. If the bearings are damaged or sealed, proceed to the next step.

2

Remove the front and side covers on the main frame. Hold the flywheel with one hand and use a box wrench to loosen the bolts that secure the pedal arms at each side of the flywheel. Pull the arms away from the flywheel and remove the bearings from each side.

3

Test the bearings as before. Lubricate exposed bearings with lithium grease and reinstall them. Sealed bearings must be replaced. Reattach the pedal arms to the flywheel. Replace the main frame covers and front top cover to complete the repairs.

Somtimes with manual gear boxes the clutch shaft wears in the spigot bearing / bush in the crank shaft or flywheel. It may be necessary to apply force evenly around the bell housing to remove the rust build up on this shaft. If you have a pull type clutch plate ( the only reason for the release arm getting tight) it will be necessary to release this arm from its pivot point first . Check the manual for this proceedure.

Step 1:

please proceed with this step . Happy new year and God bless you
Lubrication

1

Detach the ends of the pedals from the crank axles. Spread a layer of machine grease over the crank axles, then reattach the ends of the pedals.

2

Remove the bolts connecting the pedals to the swing arms. Detach the pedals from the arms, then spread a layer of machine grease over the axles on the swing arms. On some models, the bolts may also serve as the axles. Reattach the pedals to the arms.

3

Remove the bolts connecting the swing arms to the elliptical's upright. Detach the swing arms from the upright, then spread a layer of machine grease over the axles on the upright. Reattach the arms to the upright

Step 2:

Pedal Arms

1

Use a flat screwdriver to unseat the tabs that hold the front top cover in place. This will expose the flywheel and pedal arm connection points. Rotate the flywheel by hand and determine whether lubrication will accomplish the repairs. If the bearings are exposed, use a grease gun with an extension nozzle and lubricate both bearings with lithium grease. If the bearings are damaged or sealed, proceed to the next step.

2

Remove the front and side covers on the main frame. Hold the flywheel with one hand and use a box wrench to loosen the bolts that secure the pedal arms at each side of the flywheel. Pull the arms away from the flywheel and remove the bearings from each side.

3

Test the bearings as before. Lubricate exposed bearings with lithium grease and reinstall them. Sealed bearings must be replaced. Reattach the pedal arms to the flywheel. Replace the main frame covers and front top cover to complete the repairs.

Step 3:

Link Arms

1

Unplug the power cord. Identify the pivot points where the lower handlebars and the footpad link arms connect at each side of the machine. Use a screwdriver to remove the inside and outside elbow covers at each connection. This will expose the pivots.

2

Put a box wrench on the lock nut at the inside of one pivot and loosen the bolt with an Allen wrench. Remove the bolt and check the assembly for nylon spacers or a bearing. If no spacer is found, proceed to the next step. Replace the nylon spacers, reassemble the connection and reattach the elbow covers. Repeat this at the opposite side of the machine.

3

Have an assistant hold a deep socket against the inside face of the pivot hub. Make sure the socket is large enough to allow the bearing to pop out. Insert the point of a flat screwdriver into the outside of the hub until it contacts the bearing. Tap the handle of the screwdriver with a hammer to remove the bearing. Repeat this to remove the bearing on the opposite side.

4

Hold each bearing next to one ear and turn the inner race with your finger. If you hear grinding noises or the bearing is rough, it must be replaced. Lubricate the bearing with lithium grease and a grease gun. Replace the bearing into the hub. Reattach the lower handlebars and footpad link arms and put the elbow covers on.

follow this steps and fix it. God bless you
Lubrication

1

Detach the ends of the pedals from the crank axles. Spread a layer of machine grease over the crank axles, then reattach the ends of the pedals.

2

Remove the bolts connecting the pedals to the swing arms. Detach the pedals from the arms, then spread a layer of machine grease over the axles on the swing arms. On some models, the bolts may also serve as the axles. Reattach the pedals to the arms.

3

Remove the bolts connecting the swing arms to the elliptical's upright. Detach the swing arms from the upright, then spread a layer of machine grease over the axles on the upright. Reattach the arms to the upright
Link Arms

1

Unplug the power cord. Identify the pivot points where the lower handlebars and the footpad link arms connect at each side of the machine. Use a screwdriver to remove the inside and outside elbow covers at each connection. This will expose the pivots.

2

Put a box wrench on the lock nut at the inside of one pivot and loosen the bolt with an Allen wrench. Remove the bolt and check the assembly for nylon spacers or a bearing. If no spacer is found, proceed to the next step. Replace the nylon spacers, reassemble the connection and reattach the elbow covers. Repeat this at the opposite side of the machine.

3

Have an assistant hold a deep socket against the inside face of the pivot hub. Make sure the socket is large enough to allow the bearing to pop out. Insert the point of a flat screwdriver into the outside of the hub until it contacts the bearing. Tap the handle of the screwdriver with a hammer to remove the bearing. Repeat this to remove the bearing on the opposite side.

4

Hold each bearing next to one ear and turn the inner race with your finger. If you hear grinding noises or the bearing is rough, it must be replaced. Lubricate the bearing with lithium grease and a grease gun. Replace the bearing into the hub. Reattach the lower handlebars and footpad link arms and put the elbow covers on.
Pedal Arms

1

Use a flat screwdriver to unseat the tabs that hold the front top cover in place. This will expose the flywheel and pedal arm connection points. Rotate the flywheel by hand and determine whether lubrication will accomplish the repairs. If the bearings are exposed, use a grease gun with an extension nozzle and lubricate both bearings with lithium grease. If the bearings are damaged or sealed, proceed to the next step.

2

Remove the front and side covers on the main frame. Hold the flywheel with one hand and use a box wrench to loosen the bolts that secure the pedal arms at each side of the flywheel. Pull the arms away from the flywheel and remove the bearings from each side.

3

Test the bearings as before. Lubricate exposed bearings with lithium grease and reinstall them. Sealed bearings must be replaced. Reattach the pedal arms to the flywheel. Replace the main frame covers and front top cover to complete the repairs.

follow this steps and fix it. God bless you

Detach the ends of the pedals from the crank axles. Spread a layer of machine grease over the crank axles, then reattach the ends of the pedals.
2

Remove the bolts connecting the pedals to the swing arms. Detach the pedals from the arms, then spread a layer of machine grease over the axles on the swing arms. On some models, the bolts may also serve as the axles. Reattach the pedals to the arms.
3

Remove the bolts connecting the swing arms to the elliptical's upright. Detach the swing arms from the upright, then spread a layer of machine grease over the axles on the upright. Reattach the arms to the upright.

Link Arms 1

Unplug the power cord. Identify the pivot points where the lower handlebars and the footpad link arms connect at each side of the machine. Use a screwdriver to remove the inside and outside elbow covers at each connection. This will expose the pivots.
2

Put a box wrench on the lock nut at the inside of one pivot and loosen the bolt with an Allen wrench. Remove the bolt and check the assembly for nylon spacers or a bearing. If no spacer is found, proceed to the next step. Replace the nylon spacers, reassemble the connection and reattach the elbow covers. Repeat this at the opposite side of the machine.
3

Have an assistant hold a deep socket against the inside face of the pivot hub. Make sure the socket is large enough to allow the bearing to pop out. Insert the point of a flat screwdriver into the outside of the hub until it contacts the bearing. Tap the handle of the screwdriver with a hammer to remove the bearing. Repeat this to remove the bearing on the opposite side.
4

Hold each bearing next to one ear and turn the inner race with your finger. If you hear grinding noises or the bearing is rough, it must be replaced. Lubricate the bearing with lithium grease and a grease gun. Replace the bearing into the hub. Reattach the lower handlebars and footpad link arms and put the elbow covers on.

Pedal Arms 1

Use a flat screwdriver to unseat the tabs that hold the front top cover in place. This will expose the flywheel and pedal arm connection points. Rotate the flywheel by hand and determine whether lubrication will accomplish the repairs. If the bearings are exposed, use a grease gun with an extension nozzle and lubricate both bearings with lithium grease. If the bearings are damaged or sealed, proceed to the next step.
2

Remove the front and side covers on the main frame. Hold the flywheel with one hand and use a box wrench to loosen the bolts that secure the pedal arms at each side of the flywheel. Pull the arms away from the flywheel and remove the bearings from each side.
3

Test the bearings as before. Lubricate exposed bearings with lithium grease and reinstall them. Sealed bearings must be replaced. Reattach the pedal arms to the flywheel. Replace the main frame covers and front top cover to complete the repairs.

see this steps and fix it. God bless you
Pedal Arms 1

Use a flat screwdriver to unseat the tabs that hold the front top cover in place. This will expose the flywheel and pedal arm connection points. Rotate the flywheel by hand and determine whether lubrication will accomplish the repairs. If the bearings are exposed, use a grease gun with an extension nozzle and lubricate both bearings with lithium grease. If the bearings are damaged or sealed, proceed to the next step.
2

Remove the front and side covers on the main frame. Hold the flywheel with one hand and use a box wrench to loosen the bolts that secure the pedal arms at each side of the flywheel. Pull the arms away from the flywheel and remove the bearings from each side.
3

Test the bearings as before. Lubricate exposed bearings with lithium grease and reinstall them. Sealed bearings must be replaced. Reattach the pedal arms to the flywheel. Replace the main frame covers and front top cover to complete the repairs.
Link Arms 1

Unplug the power cord. Identify the pivot points where the lower handlebars and the footpad link arms connect at each side of the machine. Use a screwdriver to remove the inside and outside elbow covers at each connection. This will expose the pivots.
2

Put a box wrench on the lock nut at the inside of one pivot and loosen the bolt with an Allen wrench. Remove the bolt and check the assembly for nylon spacers or a bearing. If no spacer is found, proceed to the next step. Replace the nylon spacers, reassemble the connection and reattach the elbow covers. Repeat this at the opposite side of the machine.
3

Have an assistant hold a deep socket against the inside face of the pivot hub. Make sure the socket is large enough to allow the bearing to pop out. Insert the point of a flat screwdriver into the outside of the hub until it contacts the bearing. Tap the handle of the screwdriver with a hammer to remove the bearing. Repeat this to remove the bearing on the opposite side.
4

Hold each bearing next to one ear and turn the inner race with your finger. If you hear grinding noises or the bearing is rough, it must be replaced. Lubricate the bearing with lithium grease and a grease gun. Replace the bearing into the hub. Reattach the lower handlebars and footpad link arms and put the elbow covers on.

Lubrication 1

Detach the ends of the pedals from the crank axles. Spread a layer of machine grease over the crank axles, then reattach the ends of the pedals.
2

Remove the bolts connecting the pedals to the swing arms. Detach the pedals from the arms, then spread a layer of machine grease over the axles on the swing arms. On some models, the bolts may also serve as the axles. Reattach the pedals to the arms.
3

Remove the bolts connecting the swing arms to the elliptical's upright. Detach the swing arms from the upright, then spread a layer of machine grease over the axles on the upright. Reattach the arms to the uprigh

Possible solution! Daewoo Lanos 98-99
Had the same problem suddenly the clutch pedal went rock hard!
The clutch was around 3 months old.
Mechanic checked - Master, Slave, Clutch Components, and inside the box, all looked okay.
Turned out the top arm of the clutch pivot rod had twisted, replaced pivot rod around AU$100.
Fixed Problem!

you may have a faulty clutch master cylinder or faulty clutch slave cylinder- leaking clutch fluid. most of the time both are replaced at the same time which should be recomended by your mechanic, the bolts to the master cylinder are very hard to get to and require the right tool.
you should be able to move car forward by selecting 1st then cranking engine till it starts, gear changes while driving are hard but not impossible. i recommend a tow truck to a local repairer.

could be a couple of things check release bearing is not binding on output shaft or the arm which holds the release bearing is not bent or worn where it pivots also check where the arm pivots point is not worn out if all checks out replace the clutch pressure plate,clutch discs,throw out bearing and pilot bearing,one more thing is a clutch disc has some springs mounted to it to absorb some of the pressure when engaging the clutch and i have seen these springs come off and get in between the clutch assembly but usually when this happens you can feel and hear some grinding metal noise.but to check all the above the transmission will have to be removed.

if you have not sorted out the T3 clutch problem by now I suggest you drop the swinging arm and take a look at the clutch operating arm and check that its got the right amount of free play also check the spring which sits halfway up the clutch arm and make sure its got some free movement also check the condition of the thrust bearing and the clutch operating arm adjuster screw, if you feel the need to remove the clutch operating arm from the gearbox end cover the arm is fixed to a lug and then held on by a pivot pin with a R clip or whatever, if this pivot pin wont move do not hit it with a hammer you will only break the lug and then have to get it welded back on ,soak it in penetrating oil and apply gentle heat, but again no hammer! it might be worth buying new thrust bearing , spring, etc before the start the job.I have had my T3 for 27 years and your problem appears new to me I can only think that unless your clutch friction plate is really warpped it can only be the adjustment at the clutch arm end. the spring etc could be working ok at rest but under pressure ? ,,,