I've rebuilt my Honda CR250 2-stroke (1998). It runs beautifully but the clutch will not work to seperate the drive. Put it in gear and it lurches forward. It's not the cable adjustment so obviously I've done something wrong in the rebuild! My prime suspects are the big nut with the tab washer in the centre of the clutch or the clutch springs. Both of these I did up as tight as I could and I'm not sure this is right? Is this where I've gone wrong? How should I do them up? If this is right, any other ideas? Thanks in advance!!
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Re: Clutch won't work!
The springs and center nut should be tight. Check the clutch for proper sequence of clutch parts. Also, be sure the clutch lever assembly and left side cover are fully in place before the clutch is assembled. First plate should be a friction plate, then metal pressure plate then friction, etc. Thrust washer & two others in the proper locations? Clutch lifter in backwards? Is the clip missing?
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I know unless they changed the design the clutches need oil to operate properly to allow Slippage when clutch is in (handle is pulled in) Are you trying to shift by rocking the bike? It should shift with the clutch engaged (Engine not running) just by rocking the bike back and forth and operating the shifter. I do know without oil on the clutches with the engine running there will be to much force put on the gears to allow them to shift plus it is a very bad Idea to ever run an engine without oil in it. Be it a 4 Stroke or a 2 stroke.
Have you just replaced the clutch? Taken out the transaxle, and put it back in? Are you sure transmission was in good condition before this? If so, review your procedure carefully to be sure you got it all back right. Watch the slave cylinder while someone depresses clutch. You should see the little plunger move slightly out and move the clutch lever back. The lever moves the release bearing inside bell housing into contact with the pressure plate. If slave cylinder doesn't move at all, try bleeding again. The plunger has to move when clutch is engaged. I'm not sure what you mean by "will shift but won't go into gear". You mean it's actually going into a gear position and car won't move? Or it won't go into any gear, period. As if you had no clutch?
A clutch issue youtend to have more of an engagement problem with 1st and reverse gear for a small time period before you notice other gears.You want to check the clutch hydrolic system for any leaks(clutch slave at transmission,clutch master,which you look for leakage on interior above clutch pedal)and at fluid resevoir.you also want to double check condition of trans fluid. strongly recommend using only HONDA BRAND MANUAL TRANS. FLUID when doing maintinance,fluid should be replaced every 30k on this car.The Honda brand fluid is like night and day on these cars,it WILL make a difference in shifting!!TRust Me on this point! Sorry now back to your main clutch issue,when driveing and you go to shift gears and normally notice grinding,with clutch pedal in shft out of gear and before engageing it into next gear do a double pump of clutch pedal then see if when continuing to next gear if it engagees smoother.if so you know you have without a dout a clutch pressure plate/disc problem. I can tell you that in twenty years the only manual transmissions themselves that ever had problems were due to outside influences(gear oil in transmission,improper driveing,etc.)let me know what you find and we can go from there..JOEL