89 CR250R EBC Clutch issues

JakeBoots
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JakeBoots
Edited Date/Time 3/30/2020 5:27pm
As part of my restoration. I installed a new Hinson basket along with the EBC Dirt Racer clutch kit.

First issue I was having was the actuator arm was hitting the top of the case to fully disengage the clutch. Pulled everything apart, everything’s there. on the other side there’s a large gap when the clutch is released between the pressure plate and the top of the lifter that the ball goes inside of.

2 things I’m unable to try: the old basket got stripped apart to reuse the old ring gear and the other, appears I accidentally threw away the old clutch pack because “I have a new one now”...

After trying to figure it out for sometime on and off I removed one of the fibers to see if it would fix my issue. It’s now snug between the pressure plate and lifter and no play in the actuator arm. So now i know I have an issue with the clutch pack.

Before I go and order a new set of plates and fibers, has anyone ran into a similar issue using an aftermarket clutch in these older bikes?
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JMCR250
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JMCR250 3/30/2020 8:57am
3/30/2020 8:57am
I think a good rule of thumb with these older clutches is to always use OEM parts if available. I know a number of people who tried aftermarket plates/springs etc. who wound up with issues. You should be able to find OEM plates for your bike.
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JakeBoots
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JakeBoots 3/30/2020 2:55pm
3/30/2020 2:55pm Edited Date/Time 3/30/2020 6:55pm
JMCR250 wrote:
I think a good rule of thumb with these older clutches is to always use OEM parts if available. I know a number of people who...
I think a good rule of thumb with these older clutches is to always use OEM parts if available. I know a number of people who tried aftermarket plates/springs etc. who wound up with issues. You should be able to find OEM plates for your bike.
Yeah they’re the same from 89-02 or 03. This COVID thing is shutting down the shops so have to wait until tomorrow to get some new ones.

The rest of the bike has been reordered as OEM other than plastics, piston and a couple of other pieces because I wanted the proper fit even if it cost more. This was the one thing I cheaped out on of course..
JMCR250
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JMCR250 3/30/2020 5:27pm
3/30/2020 5:27pm
Good luck. I'm pretty confident it'll be OK with OEM plates. A friend bought an '82 125 with aftermarket plates and springs already installed. The bike runs great, but the clutch will wear out your left hand in a few laps.
JakeBoots
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JakeBoots 3/30/2020 6:58pm
3/30/2020 6:58pm
Played around again tonight. Found the issue to somehow be the Hinson basket. It’s strange as the primary gear is inserted properly and flush in the Center of the basket. But when measuring the clutch pack using the thrust washer I got a difference of 1.8mm in height.

I emailed Hinson already just now but tomorrow am going to lap down the thrust washer 1.8mm (from 4.8mm down time 3mm) and I believe this should solve my problem!

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CDswinehart
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CDswinehart 3/31/2020 10:20am
3/31/2020 10:20am
FWIW: When we were representing EBC at the pro races (1985 - 2002) we used mostly the Kevlar kits but some of the regular material kits also. There were very few aftermarket clutch basket/hub combos out in the market so mostly the fitment was to stock components.

The issues I remember was not plates in the basket, but usually condition of basket/hub itself (privateer's w/o parts budget) and the EBC kit springs being too stiff compared to stock. The common setup was to use three (3) of the kit springs and the others stock,, or new stock springs all around.

The type of gearbox oil was less important it seemed (10-40 engine oil, gearbox oil, tractor UTF, Ford type F) than it was to pre soak the friction plates first before installation. Any oil of course being wet clutch compatible.

As with all things moto, do your own tests, your mileage may vary.

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