cr250 clutch won't disengage?

cr250rman
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cr250rman
Edited Date/Time 1/16/2015 11:45am
I seem to be having a problem with my clutch, my cr250 has a brand new lever and perch new cable and i just put in fresh plates and springs. ever sense i put the new cable on my clutch won't disengage I've been trying to mess with all the adjustments and nothing works. anyone have any idea?
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Falcon
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Falcon 3/4/2014 2:07pm
3/4/2014 2:07pm
There is likely not enough play in your new cable. Check the inline adjuster on the cable that is located somewhere close to the lever end. You should loosen the lock nut and then turn the adjuster nut clockwise on the threads (making the cable sheath shorter overall.) You should not need a whole lot of adjustment.

If this is not the case, make sure you put the plates in correctly - there should be alternating metals and fibers, with metal plates on each side of the stack.

Also, if your basket has grooves, the plates can hang up on it and not disengage. Check the tines of the clutch basket for rough edges or worn spots.
cr250rman
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cr250rman 3/4/2014 2:13pm
3/4/2014 2:13pm
i definitely know the plates are in correctly, and I'm not sure about the basket its probably not fancy like the newer bikes :p lol its a 1990 cr250 i was playing with the clutch before i put the cover on and everything looked as it was moving freely, its probably the cable now that you say that ill go mess with it some more
cr250rman
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cr250rman 3/6/2014 1:01pm
3/6/2014 1:01pm
ok I'm back to the same problem, i know the clutch plates are in correctly because i just put them in about 4 days ago, it has a brand new cable and lever and perch I've been trying to mess with the adjustments and it still doesn't disengage, i know when i had the side cover off i was pulling in the lever and everything was moving freely. Anyone have any idea? i didn't get this problem until i put the new cable and perch/lever on, i compared both the old and new cable and there exactly the same size.

The Shop

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cr250rman
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cr250rman 3/6/2014 1:56pm
3/6/2014 1:56pm
I can adjust it to have play at the lever yes, the clutch feels and pulls nicely when i loosen it. but the back wheel is still dragging. i know when i pulled the other side cover off to put the cable on the lever it connects to inside the motor goes all the way up when i pull the lever in all the way. which is what its suppose to do, yet the back wheel is still dragging
Paw Paw 271
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Paw Paw 271 3/6/2014 2:21pm
3/6/2014 2:21pm
If you are talking about the rear tire "dragging " while the engine is not running and you are in gear.....That will never change.
It is the nature of motorcycles as the gearing is that way. It's not like a car.
cr250rman
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cr250rman 3/6/2014 2:28pm
3/6/2014 2:28pm
I do understand that, I'm talking when its in gear and you pull the clutch in the bike should roll freely. but it doesn't because the clutch isn't disengaging when i pull it in
MOTODAD422
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MOTODAD422 3/6/2014 2:46pm
3/6/2014 2:46pm
If the engine is cold that is normal,when hot, it should roll easier.
cr250rman
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cr250rman 3/6/2014 2:50pm
3/6/2014 2:50pm
are you sure? ill try to warm it up and see if that does anything, but i mean if i put it in gear pull the clutch in and try to roll it you can hear the motor turning over
project racer 3/6/2014 3:02pm
3/6/2014 3:02pm
Take the bike off the stand, put it in second gear, pull the clutch lever in , then rock the bike back and forth. Usually when the plates are stuck a bit, this will free things up.

If not, go back over your work carefully.
Paw Paw 271
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Paw Paw 271 3/6/2014 3:24pm
3/6/2014 3:24pm
Did you soak the fiber clutch plates in oil before the install?
cr250rman
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cr250rman 3/6/2014 3:30pm
3/6/2014 3:30pm
yes they soaked over night, like i said it was doing this before i put the new plates in so i don't think its that. it started when i put the new cable on which was about a month ago i just put the plates in 4 days ago
mx5471
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mx5471 3/6/2014 4:39pm
3/6/2014 4:39pm
You have to trouble shoot things from the beginning . If all was good until you changed the cable, I would look at that first. Forget the basket notches, as it would work but be erratic. Simple diagnostic technique , if it worked before you changed something, as doesn't work after, the answer is what you did.
cr250rman
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cr250rman 3/6/2014 7:58pm
3/6/2014 7:58pm Edited Date/Time 3/6/2014 7:58pm
okie dokes thanks Smile
Paw Paw 271
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Paw Paw 271 3/7/2014 8:32am
3/7/2014 8:32am
Do you feel any resistance when you pull in the clutch lever? If not, then check the arm under the stator case and make sure it is fully engaging the push rod to the clutch.
cr250rman
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cr250rman 3/7/2014 9:09am
3/7/2014 9:09am
Yep pulled that of twice already it goes all the way to the top, both me and my dad can't figure out whats wrong with it so I'm just going to take it in.
Paw Paw 271
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Paw Paw 271 3/7/2014 1:41pm
3/7/2014 1:41pm
Have you removed the arm to be sure the cam end is not worn off? This is a common issue that needs to be checked.

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cr250rman
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cr250rman 3/7/2014 2:03pm
3/7/2014 2:03pm
Would the plates still move up and down when i pull in the lever even if this was worn?
Paw Paw 271
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Paw Paw 271 3/7/2014 2:46pm
3/7/2014 2:46pm
Yes it would still move the plates, but not enough to totally release the clutch pressure so as to have the clutch disengage fully.
cr250rman
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cr250rman 3/7/2014 2:57pm
3/7/2014 2:57pm
hmmm ok that might be the problem i mean i know its been in there for years I'm sure, how hard is it to pull off and check? and what does it look like so i know what I'm looking for,
Paw Paw 271
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Paw Paw 271 3/7/2014 3:25pm
3/7/2014 3:25pm Edited Date/Time 3/7/2014 3:27pm
As I recall, the flywheel has to come off to fully remove the arm. You also need to take off all the pressure from the clutch pressure plate. Then you should be able to pull it out. The arm has a cam on the end of the rod that pushes the rod that goes to the clutch. It has to have a good bit of rise in it to work. Does your manual show it?
http://www.bikebandit.com/houseofmotorcycles/1990-honda-cr250r/o/m11897…
Look at part numbers 6.

Paw Paw
Sugashaneco
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Sugashaneco 1/16/2015 11:45am
1/16/2015 11:45am Edited Date/Time 1/16/2015 11:54am
I had the exact same problem on my '01 CR250R and found out that it was the clutch basket. I had the exact same issues, thought it was the clutch because i was thinking backwards so I put a new clutch in, still couldn't get the clutch to disengage when i got everything back together. I drained the new honda oil i just put in, pulled out the clutch disks and plates and noticed i had a hard time removing them just like when i put them in. After removing them i noticed the slots that the clutch disks slide into looked serrated like a knife. As soon as i got the clutch plates and disks out i noticed i could spin the sproket while bike was in 1st gear like it should.(no chain attached to my sproket) where before it would just be locked up when its in 1st
The clutch disks get caught in the groves and wont release.

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