New clutch not working right

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11/16/2017 10:05 AM

In the process of building this 2001 cr125. I installed a brand new clutch kit. I got the engine back on the frame and everything hooked up. When I pull the clutch lever in, it's really hard to squeeze. I use some heavy duty grippers to work out my grip strength with (starting at 100 pounds grip force going up to around 350 pounds) and it feels as hard as the 100 pound gripper. I know it should not feel this hard. It should feel smooth as butter. And yes, I have a brand new clutch cable installed already!! Also when I pull it in and I go to see if the transmission turns it won't. So basically the clutch is doing nothing. So my problems are: 1) clutch is extremely hard to squeeze and 2) clutch is not working at all

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11/16/2017 11:29 AM

Ive had luck in the past by replacing that actuator arm that sticks out of the case. For whatever reason it corrodes or wears out or somethig and becomes hard to pull.

It could be an adjustment thing or springs that are too stiff. Also it becomes easier when the bike is running and the clutch has oil all over and inbetween the plates. If its dry it wouldnt surprise me one bit that its stiff.

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2009 Kawasaki KX450F
2009 Kawasaki KX250F
2002 Suzuki GSXR 600

11/16/2017 11:41 AM

Acidreamer wrote:

Ive had luck in the past by replacing that actuator arm that sticks out of the case. For whatever reason it corrodes or wears out or somethig and becomes hard to pull.

It could be an adjustment thing or springs that are too stiff. Also it becomes easier when the bike is running and the clutch has oil all over and inbetween the plates. If its dry it wouldnt surprise me one bit that its stiff.

When the clutch wasn't in the actuator arm moved just fine. Also the clutch plates were soaked in oil a few days before installed.

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11/16/2017 11:50 AM
Edited Date/Time: 11/16/2017 11:50 AM

I pulled the stator cover off and the actuator arm is moving like it should yet the clutch is still not working and hard to move?

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11/16/2017 12:16 PM

Here's a video. I took the cover off and here's what happens when I squeeze the clutch. Does everything look normal to y'all?

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11/16/2017 12:17 PM

And here's a photo of it
Photo

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11/16/2017 12:23 PM

If these are new springs, and you have no idea how they should feel, then the springs are probably really tight. Toss in some old springs if you have them and see if that gives you the "feel" that you think it should have.

Also, I don't think that pulling the clutch lever on a brand new, oil soaked clutch kit, with no run time is going to allow you to just "spin" the transmission if its in gear. When you pull the lever, you probably still have a lump of clutch plates all stuck together. You really need the engine vibration, heat, spinning crankshaft, etc... to help in disengaging the power transfer.

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11/16/2017 3:00 PM

Micahdogg wrote:

If these are new springs, and you have no idea how they should feel, then the springs are probably really tight. Toss in some old springs if you have them and see if that gives you the "feel" that you think it should have.

Also, I don't think that pulling the clutch lever on a brand new, oil soaked clutch kit, with no run time is going to allow you to just "spin" the transmission if its in gear. When you pull the lever, you probably still have a lump of clutch plates all stuck together. You really need the engine vibration, heat, spinning crankshaft, etc... to help in disengaging the power transfer.

Ok but does it look like everything is leaned to one direction to you? Look at the center piece. Is that normal?

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11/16/2017 3:45 PM

No... that is not normal, you need to disassemble that clutch pack. ASAP. Post pics of the clutch pieces and HOPE Paw Paw is around!

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11/16/2017 3:53 PM

Ti wrote:

No... that is not normal, you need to disassemble that clutch pack. ASAP. Post pics of the clutch pieces and HOPE Paw Paw is around!

I noticed when I put the inner clutch hub in that one side seemed to poke out a little more. Maybe that's causing the problem?

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11/16/2017 3:54 PM

How would I know if it's straight or what to replace?

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11/16/2017 4:13 PM



Photo

Here is the schematic. For your clutch to be off center like that... you either do not have all the parts installed correctly, or a part or parts are worn out. Your engine would vibrate a LOT if you ran it, as in the picture. Looks like the clutch basket is worn??? There is a video on youtube. search: Dirt bike/motorcycle clutch rebuild/install Cr125.
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11/16/2017 4:24 PM

Ti wrote:

Photo

Here is the schematic. For your clutch to be off center like that... you either do not have all the parts installed correctly, or a part or parts are worn out. Your engine would vibrate a LOT if you ran it, as in the picture. Looks like the clutch basket is worn??? There is a video on youtube. search: Dirt bike/motorcycle clutch rebuild/install Cr125.

There are no parts missing and everything is in correct order. And my outer clutch basket? It looks good to me.

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11/16/2017 5:01 PM

I am on a phone, so maybe it is just the angle of the picture. When looking straight at your clutch, the springs and bolts should be centered and your plate/ clutch lifter [part 9] needs to be centered on the pressure plate. just noticed at the 2 o'clock position of the basket that the tab has a chip out of it... so I thought maybe you have a excessively grooved clutch basket and the fiber plates were getting stuck in the grooves thus making the clutch pull extreme. Anyway if there are no parts missing and assembled correctly and the parts are not worn... only other thing is make sure the new clutch cable is not hung up anywhere.

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11/16/2017 5:11 PM

You said new clutch...
Then why is there wear showing on the top fiber plates fingers?
Is the clutch basket notched? If so and new fibers are installed then the fibers no longer align with the notches in the basket and thus they will catch on the groves.
RE: Center bearing.... Yes it floats and can be off center.
I suspect worn basket and may be even inner hub.

Paw Paw

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11/16/2017 5:17 PM

Paw Paw wrote:

You said new clutch...
Then why is there wear showing on the top fiber plates fingers?
Is the clutch basket notched? If so and new fibers are installed then the fibers no longer align with the notches in the basket and thus they will catch on the groves.
RE: Center bearing.... Yes it floats and can be off center.
I suspect worn basket and may be even inner hub.

Paw Paw

The basket does have a small chip but I don't think it'll hurt anything? Also the plates aren't worn they just look like that. So the inner hub would cause this?

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11/16/2017 5:31 PM

My clutch is going in normally based on the videos I've watched, so if it's moving right then why would it not work?

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11/16/2017 7:46 PM

So how will I know if my basket or inner hub needs to be replaced? I'm pulling it out tomorrow. What should I look for?

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11/16/2017 8:56 PM

Anyone?

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11/16/2017 11:36 PM
Edited Date/Time: 11/16/2017 11:37 PM

It shouldnt have any up down, side to side movement. Or the obvious loose or missing needles in the bearings.

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11/16/2017 11:56 PM

You are looking for notches or rough spots and also make sure each fiber plate moves freely on the splines of the inner hub and the openings of the outer hub. Also be sure the basket and inner hub spin freely.

Paw Paw

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11/17/2017 9:47 AM

I not sure if it's supposed to have these grooves or not. Does this look good to y'all?Photo

Photo

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11/17/2017 10:01 AM

Nevermind I did some research and this seems to be the cause of my problem. So I either need to grind it down or buy a new one, and right now I can't afford a new one so grinding will do.

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11/17/2017 10:04 AM

Now onto the inner hub. It has notches as well but they're barely noticeable. Should I replace it? Also how would I know if my inner hub is uneven? I think it might be causing the leaning of everything as shown in the photo.

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11/17/2017 11:17 AM

Id replace both. The width of the slots on the basket are critical for the clutch to work right. Also if you dont do it straight youll be in the same boat youre in. You can get used baskets in good condition for cheap on ebay. Hell even some billet aftermarket ones are only $250.

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2009 Kawasaki KX450F
2009 Kawasaki KX250F
2002 Suzuki GSXR 600

11/17/2017 11:48 AM

Acidreamer wrote:

Id replace both. The width of the slots on the basket are critical for the clutch to work right. Also if you dont do it straight youll be in the same boat youre in. You can get used baskets in good condition for cheap on ebay. Hell even some billet aftermarket ones are only $250.

Only $250??

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11/17/2017 11:54 AM

The basket groves are not normal and are causing the problem as the fiber plates are hanging on them.
There is no way to get the grind even on all the basket openings for the fiber plates. This will result in some very un even side loads on the fibers and they will break and that could cause many more problems and damage.
FYI: The last photo shows that some one has already tried to grind or file these same places.
Replace both inner hub and basket before you cause even greater damage or get hurt while riding.

Paw Paw

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11/17/2017 12:35 PM

Acidreamer wrote:

Id replace both. The width of the slots on the basket are critical for the clutch to work right. Also if you dont do it straight youll be in the same boat youre in. You can get used baskets in good condition for cheap on ebay. Hell even some billet aftermarket ones are only $250.

z71will wrote:

Only $250??

You wanna replace 10 oem ones or 1 aftermarket one?

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2009 Kawasaki KX450F
2009 Kawasaki KX250F
2002 Suzuki GSXR 600

11/17/2017 12:40 PM

I bought a new inner clutch hub but I have $0 more to spend on this bike

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1/22/2018 12:21 PM

z71will wrote:

I bought a new inner clutch hub but I have $0 more to spend on this bike

Any update on this? I had a similar issue. My clutch basket was worse than yours and my hub was also not too good. Ordered both last night along with new plates and new shift pawl springs and a couple other small things for the shift mechanism.

My bike got to where I had 1st, 2nd and neutral but couldn’t go up to 3rd. Found broken friction plate fragments when I pulled the side of the case cover off. Excited to get it going again after I get my new clutch and shift components in. It’s a 97 yz125

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