HELP!!!Baja dirt runner 125 clutch assembly
 

Hi everyone new to the forum and looking to get some feedback on my recently purchased Baja 125 dirt runner! Picked the bike up for cheap ran fairly decently when purchased but the clutch cable was snapped and tires both flat, replaced clutch cable and could not get the clutch to disengage while in gear so the bike could not roll with the lever on the crankcase fully engaged.... drained oil removed crankcase cover and removed clutch basket assembly and inspected. I’m not familiar with these but everything looked normal and the friction disc are not glazed and no shavings of metal in the oil. My first guess was possibly springs are bad, there isn’t a manual out for this bike that I know of just wondering if I missed something or maybe someone installed parts wrong before I got the bike.... anything helps... also I did find an electronic parts catalog and it looks like all the parts for the clutch basket assembly are there and installed in proper order

Welcome aboard! If the bike was set up for a while the disc may be stuck together. Try laying the bike on its side over night on the clutch side. The dried out disc will soak up some oil and this might get them unstuck. If not you will need to pull the clutch pack as separate them manually. You can get the entire clutch pack for under $20.

Thanks for the advice as I said above I have already removed the clutch basket and the disc seem fine they are not stuck

Sorry, I missed that. :doh:

Do you think the actuator rod is worn down too much to disengage the clutch?

I’m not really sure which part that is if you are referring to the pin inside the bearing assembly it is fine I can see very little wear on it it’s painted black and has very light silver scoring so I would say it’s fine

Try adjusting the clutch at the engine. Here's a tutorial on how to do it. https://tboltusa.com/store/tech.php?...tch+Adjustment

That is a lot different then my clutch assembley I do not see any adjustments [/PHP]

Something doesn't look right in the bottom pic, it looks as though you don't have enough clutch plates under the outer pressure plate, it is recessed inward. Normally, that outer pressure plate sits flush with the outer edges of the clutch basket.

Ok thanks I’ll try that and get back to you!

This is a current picture they way I have it installed now with tension on springs but the clutch basket can slide with my hand if I hold the outer assembly

It just as 90's kick ONLY CG125. If u search 'net: Haynes (pre CDI model) & CGR125 storm (e-start model ) service manual pdf can easily found . The one (Kick ONLY, CDi) resembles ur bike's engine is in Brazilian Portuguese. :doh:
Unusual way to repair old CG http://www.chyangwa.net/forum.php?mo...authorid=75082

Ok thanks it looks like I am missing a piece that sits in front of the bearing

Oh I see you have a cg125 and not horizontal 125. You have the same style clutch as the cg250. I have couple of manual I can email you tomorrow. I don't have them on my home computer.

Ok thanks appreciate all the help, this forum is great!