New guy with Clutch problems!!!

dwatts1984 · 12-18-2012, 06:53 AM

So i picked up a nice little Jet Moto 250cc Dirt bike some time ago for next to nothing. Had an oil leak do to someone rebuilding the top end without a gasket... Used RTV instead. Anyhow upon fixing that, and replacing the stator and flywheel, I got the bike roaring to life!!! Sounds mean, fast throttle response, and idles smooth...

However, with every triumph there is a set back! My clutch is completely inoperable. Pull the clutch and it does nothing. Tried adjusting the cable. Still nothing. Pulled the cable itself as far as it would allow... still nothing. Upon removing the clutch cover... I noticed there is a mushroom head push-rod in the middle of the clutch basket... It can be removed with my fingers. I didn't find any springs behind it. Or in front of it. there was nothing there but the push rod.

I feel like something is missing. When you look at the clutch cable mechanism... it appears its supposed to push the "pushrod in" to the clutch basket to engage the clutch and pull it out to disengage it. However because there is a spring or something missing... nothing works.

Help... I'm flying blind here! I'm really good at reverse engineering things. But I feel like something is missing. Because someone touched it before me, I have no way of knowing anything.

Pease help! Holidays are here and my son really wants to ride.

Weldangrind · 12-18-2012, 09:52 AM

Does this help? The number of clutch plates is immaterial; the rest of the components should be the same.

http://www.cmsnl.com/honda-xr200r-19...8.html#results

humanbeing · 12-18-2012, 09:51 PM

Does this video give u the idea?

Weldangrind · 12-19-2012, 01:43 AM

That cost the guy in the video $40! 8O

humanbeing · 12-19-2012, 05:25 AM

Quote:

Originally Posted by Weldangrind

That cost the guy in the video $40! 8O

It's std market price in Pear River Delta for that kind of job. Parts costs ~$20 already.
Some mechanic had lower quotation in Guangdong because had "brain power". :P 100k+ km bike

dwatts1984 · 12-19-2012, 07:03 AM

The video kinda helped... I saw it earlier. However the pushrod on that clutch is different from mine. His has a long skinny push rod and the one on my bike is thicker and mushroomed :oops:

Im lost... Wish I woulda had this thing before someone screwed with it!

Weldangrind · 12-19-2012, 10:21 AM

I think the type you're describing is the Honda XR200 version that I linked to above.

dwatts1984 · 12-20-2012, 06:48 AM

Quote:

Originally Posted by Weldangrind

I think the type you're describing is the Honda XR200 version that I linked to above.

Thats exactly right! The picture shows that I have everything...? However clutch is still not existent... Doesnt work... I can pull the cable and lever and nothing happens. It the clutch actuated by fluid inside... Im so lost.

66Sprint · 01-01-2013, 01:11 AM

Unsure about your exact clutch, but on the Hondas, it is possible to install the pressure plate so that its internal splines sit atop of the splines of the clutch center instead of "meshed" with them, and thus the clutch is always released..... A sequence of 1/4 turns will let you find the correct orientation as the parts will manually slide together enough to clamp the plates together with light pressure when correct......
I may still have the pieces and be able to take pics showing the orientation differences......I'll post them here if I can dig out those parts from the spares boxes....

ricerocketc · 02-10-2013, 07:01 PM

Does anyone know what that tool is he used around 1:30 in the video? A compression nut tool or something?? Wondering where I can buy one, I'm going to rebuild my clutch before spring and that tool would make the job a lot easier!

Weldangrind · 02-11-2013, 09:42 PM

This will do it. It will remove the nut behind the centrifugal oil pump cover, as well as the clutch. An impact wrench is an ideal way to drive it.

http://www.ebay.ca/itm/Clutch-Tool-H...641dfe&vxp=mtr

ricerocketc · 03-19-2013, 11:35 PM

Installed new clutch plates -made sure to pre soak them in oil, and put everything back together. Took the bike for a test ride this morning and noticed the clutch slipping quite a bit. I backed off the cable to completely slack and its grabbing better but if I slap on the throttle there's still some slip before it grabs. Is this normal? does it need some break in?

Weldangrind · 03-25-2013, 12:34 AM

It shouldn't need any break-in time. What type of oil are you using?

ricerocketc · 03-26-2013, 01:32 PM

10w40 for 4stroke/wet clutch. Took it for a ride this past weekend and everything is good. Maybe the plates were just a bit oversaturated with oil if thats possible?...

Changing clutch plates on this bike is super easy, the hardest part was finding the parts. Chinaparts depot had a full clutch package for about 80 bux but the sproket was about 2mm larger in diameter. But just take the plates out of the housing and use them in your old one. Works like a charm

Weldangrind · 03-26-2013, 03:51 PM

Glad to hear that it works properly now. It never occurred to me that the plates might be saturated.

12-18-2012, 06:53 AM	#1
dwatts1984 Join Date: Dec 2012 Posts: 7	New guy with Clutch problems!!! So i picked up a nice little Jet Moto 250cc Dirt bike some time ago for next to nothing. Had an oil leak do to someone rebuilding the top end without a gasket... Used RTV instead. Anyhow upon fixing that, and replacing the stator and flywheel, I got the bike roaring to life!!! Sounds mean, fast throttle response, and idles smooth... However, with every triumph there is a set back! My clutch is completely inoperable. Pull the clutch and it does nothing. Tried adjusting the cable. Still nothing. Pulled the cable itself as far as it would allow... still nothing. Upon removing the clutch cover... I noticed there is a mushroom head push-rod in the middle of the clutch basket... It can be removed with my fingers. I didn't find any springs behind it. Or in front of it. there was nothing there but the push rod. I feel like something is missing. When you look at the clutch cable mechanism... it appears its supposed to push the "pushrod in" to the clutch basket to engage the clutch and pull it out to disengage it. However because there is a spring or something missing... nothing works. Help... I'm flying blind here! I'm really good at reverse engineering things. But I feel like something is missing. Because someone touched it before me, I have no way of knowing anything. Pease help! Holidays are here and my son really wants to ride.
	0

12-18-2012, 09:52 AM	#2
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Does this help? The number of clutch plates is immaterial; the rest of the components should be the same. http://www.cmsnl.com/honda-xr200r-19...8.html#results __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

12-19-2012, 01:43 AM	#4
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	That cost the guy in the video $40! 8O __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

12-19-2012, 07:03 AM	#6
dwatts1984 Join Date: Dec 2012 Posts: 7	Video The video kinda helped... I saw it earlier. However the pushrod on that clutch is different from mine. His has a long skinny push rod and the one on my bike is thicker and mushroomed :oops: Im lost... Wish I woulda had this thing before someone screwed with it!
	0

12-19-2012, 10:21 AM	#7
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	I think the type you're describing is the Honda XR200 version that I linked to above. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

12-18-2012, 09:51 PM	#3
humanbeing Join Date: Mar 2008 Posts: 2,436	Does this video give u the idea?
	0

01-01-2013, 01:11 AM	#9
66Sprint Join Date: Nov 2012 Location: Roanoke, Virginia Posts: 76	Unsure about your exact clutch, but on the Hondas, it is possible to install the pressure plate so that its internal splines sit atop of the splines of the clutch center instead of "meshed" with them, and thus the clutch is always released..... A sequence of 1/4 turns will let you find the correct orientation as the parts will manually slide together enough to clamp the plates together with light pressure when correct...... I may still have the pieces and be able to take pics showing the orientation differences......I'll post them here if I can dig out those parts from the spares boxes....
	0

02-10-2013, 07:01 PM	#10
ricerocketc Join Date: Aug 2012 Posts: 13	Does anyone know what that tool is he used around 1:30 in the video? A compression nut tool or something?? Wondering where I can buy one, I'm going to rebuild my clutch before spring and that tool would make the job a lot easier!
	0

02-11-2013, 09:42 PM	#11
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	This will do it. It will remove the nut behind the centrifugal oil pump cover, as well as the clutch. An impact wrench is an ideal way to drive it. http://www.ebay.ca/itm/Clutch-Tool-H...641dfe&vxp=mtr __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-19-2013, 11:35 PM	#12
ricerocketc Join Date: Aug 2012 Posts: 13	Installed new clutch plates -made sure to pre soak them in oil, and put everything back together. Took the bike for a test ride this morning and noticed the clutch slipping quite a bit. I backed off the cable to completely slack and its grabbing better but if I slap on the throttle there's still some slip before it grabs. Is this normal? does it need some break in?
	0

03-25-2013, 12:34 AM	#13
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	It shouldn't need any break-in time. What type of oil are you using? __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-26-2013, 01:32 PM	#14
ricerocketc Join Date: Aug 2012 Posts: 13	10w40 for 4stroke/wet clutch. Took it for a ride this past weekend and everything is good. Maybe the plates were just a bit oversaturated with oil if thats possible?... Changing clutch plates on this bike is super easy, the hardest part was finding the parts. Chinaparts depot had a full clutch package for about 80 bux but the sproket was about 2mm larger in diameter. But just take the plates out of the housing and use them in your old one. Works like a charm
	0

03-26-2013, 03:51 PM	#15
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Glad to hear that it works properly now. It never occurred to me that the plates might be saturated. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0