125 lifan clutch not fully disengaging

[benhonda]

I bought a bike with the 125 lifan 4 speed manual clutch
When I got it, the clutch would not fully disengage, causing downshifts to be rough or require the right engine speed and when you would come to a stop the bike would try to move in 1st gear with the clutch lever pulled and if you held the brake it would cause the motor to stall.


So I bought a new clutch...and the bike is doing the same thing!


Any ideas? I have tried adjusting the clutch cable and the screw behind the plate. I can adjust the cable until the clutch never fully engages...and still not have it fully disengage when I pull the lever. So I don't believe this is an issue with the cable/lever or any adjustment outside of the case.


For now, I have some generic 4 stroke 10 or 15-40 oil. It shouldn't cause this issue that I don't have a motorcycle specific oil right?

[JerryHawk250]

You have a wet clutch system so should be using oil rated for wet clutch. I think the problem is probably either swollen or warped clutch disc that is causing the clutch to drag. Its possible the previous owner overheated the clutch. A new clutch pack is about $20.

[benhonda]

Originally Posted by JerryHawk250

You have a wet clutch system so should be using oil rated for wet clutch. I think the problem is probably either swollen or warped clutch disc that is causing the clutch to drag. Its possible the previous owner overheated the clutch. A new clutch pack is about $20.

the problem existed when I got the bike, but I just put a new clutch in last night and still have the same issue.


The only other thing I can think of is that the new clutch didn't come with the cover/front plate that has the ball bearing. I didn't see anything wrong with the old one, but since it the problem existed before and still does now it makes me wonder. Of course, I'd have to buy another clutch from somewhere else to get that part and wait another week or more for it to arrive.

[JerryHawk250]

Originally Posted by benhonda

the problem existed when I got the bike, but I just put a new clutch in last night and still have the same issue.


The only other thing I can think of is that the new clutch didn't come with the cover/front plate that has the ball bearing. I didn't see anything wrong with the old one, but since it the problem existed before and still does now it makes me wonder. Of course, I'd have to buy another clutch from somewhere else to get that part and wait another week or more for it to arrive.

Okay, I missed that part about the new clutch. I just read your other thread.

[benhonda]

Originally Posted by JerryHawk250

Okay, I missed that part about the new clutch. I just read your other thread.

Yeh, I thought that maybe more Dirt guys would have these engines/clutches and could give me some ideas of things to check.
Just getting frustrated, there isn't many videos online for these, and I can't find a single exploded view for the clutch or gearbox. I'm a visual learner, and I'm pretty sure I put everything back the way it was when I installed the new clutch...but then, I don't know if the previous person put things back in the right order. So there could be something not right but without a reference I'm out of luck.

[JerryHawk250]

I have a service manual but is for an auto clutch. You have a Hellcat right? You can get all the parts from here. https://partskit.com/product/search/...hicles&vc=0591

[JerryHawk250]

TBolt has some good tutorials. https://tboltusa.com/store/tech.php?...tch+Adjustment

[JerryHawk250]

Do you this the actuator rod is too worn down to disengage the clutch all the way?