cr 250 clutch help

Schwanz22
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Schwanz22
Edited Date/Time 6/12/2014 9:41am
hey guys, I bought a new clutch cable to put my CR 250, the cable seems longer than the one that wasn't it but after installing it there is no play in the clutch whatsoever. The old cable seem to have play in it and when I rode the bike the clutch seems to work fine was just wanting to see if anybody had any ideas why there is no slack in the clutch with the new cable installed, and if there's any chance of the clutch itself could be bad. Thanks guys, I appreciate any help.
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Schwanz22
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Schwanz22 5/23/2014 3:40pm
5/23/2014 3:40pm
sorry for any errors in typing, I'm driving down the highway and using voice text.
Vecchia Scuola 5/24/2014 7:36am
5/24/2014 7:36am
There must always be a little "play" on the cable other wise you'll cook it too soon.
How ever you should give some play trought the adjuster up on the lever,ain't it?
xnationalwrench 5/24/2014 6:29pm
5/24/2014 6:29pm
Vecchia Scuola wrote:
There must always be a little "play" on the cable other wise you'll cook it too soon. How ever you should give some play trought the...
There must always be a little "play" on the cable other wise you'll cook it too soon.
How ever you should give some play trought the adjuster up on the lever,ain't it?
Another place to look at is the in-line cable adjuster.
Schwanz22
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Schwanz22 5/24/2014 8:03pm
5/24/2014 8:03pm
Both the in line adjuster, and the perch adjuster are all the way in... I'm totally lost...

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Vecchia Scuola 5/27/2014 1:36pm
5/27/2014 1:36pm
Schwanz22 wrote:
Both the in line adjuster, and the perch adjuster are all the way in... I'm totally lost...
Just customize it!
I mean make a new cable "do it yourself" and problem solved Wink
Marco Garver 5/27/2014 1:50pm
5/27/2014 1:50pm
Clutch rebuilt?

If the friction plate stack is not thick enough you will run out of adjustment.

Regards Marco
xnationalwrench 5/27/2014 3:26pm
5/27/2014 3:26pm
Are you sure it is the correct cable? Measure the overall length of both cables and see what the difference is., you can do the same check measuring that sheath of each cables. You did not mention which year bike you have so it is possible you got a different year or even maybe a crf cable.
Schwanz22
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Schwanz22 5/27/2014 3:51pm
5/27/2014 3:51pm
It's on a 1993 Cr250. At first I ordered the motion pro cable. The motion pro is about two to three inches longer than the cable that was on my bike (not sure if it's the right cable or not). So then I ordered a oem cable. It's exactly like the motion pro cable... both of which fit better than the cable that was on my bike...
Schwanz22
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Schwanz22 5/27/2014 3:56pm
5/27/2014 3:56pm
I'm wondering if the clutch plates are worn enough to not have any slack at the cable... it's been a long time since I've had to work on a dirt bike so I'm re familiarizing myself with it haha. Is there any other checks I can do to see what's going on?
captmoto
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captmoto 5/27/2014 7:16pm
5/27/2014 7:16pm
Compare the exposed length of the old cable to the new cables. It can be a little longer due to stretch but should be close. If it is off by much you then need to figure out how to deal with that. A worn clutch stack is thinner than a new one so a new clutch will have less slack to play with. Make sure the cable slack adjuster is seated where it comes together.
Schwanz22
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Schwanz22 5/27/2014 9:30pm
5/27/2014 9:30pm
The new cable is about 1 -1.5 inches longer than the old cable. I would think that would give more slack, not less... this is pretty confusing.. I think I'll pull my clutch cover and see what the plates look like.. I know when I rode the bike before I naught it, the clutch worked fine. I have a feeling that the cable that was on my bike was not made for this bike.. I'll try to post some pics when I get home from work tomorrow of the two cables..
RyanLester761
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RyanLester761 5/28/2014 4:41pm
5/28/2014 4:41pm
captmoto wrote:
Compare the exposed length of the old cable to the new cables. It can be a little longer due to stretch but should be close. If...
Compare the exposed length of the old cable to the new cables. It can be a little longer due to stretch but should be close. If it is off by much you then need to figure out how to deal with that. A worn clutch stack is thinner than a new one so a new clutch will have less slack to play with. Make sure the cable slack adjuster is seated where it comes together.
I agree. The exposed cable length is what determines the slack/adjustment. It sounds like you checked that though...

Is there a push rod on your bike? (My '01 CR125 has one) Maybe the pushrod is hung up on the actuating arm somehow???
Schwanz22
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Schwanz22 5/29/2014 9:55pm
5/29/2014 9:55pm
Here's a pic of the lower cable connection... everything looks normal I think...




project racer 5/30/2014 11:17am
5/30/2014 11:17am
Looking at the picture, is the little ferrel end of the cable pushed all the way into the case ? Looks like it could go in a little bit further. If you have the old cable, see how deep it went in compared to the new one.
Schwanz22
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Schwanz22 6/1/2014 9:31pm
6/1/2014 9:31pm
I think it's in all the way, I'll compare it to the other cable though
Schwanz22
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Schwanz22 6/12/2014 9:41am
6/12/2014 9:41am
Well... after doing everything else, I checked the plates. They weren't real bad, but the steels had grooves in them. Replaced it just now and BAM!!! good as new haha. Thanks everyone for the suggestions though. Sometimes the simplest solution is the right one all along. .

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