Vintage Dirt Bike Q & A

Anyone seen this before? Warm or cold, at rest, I cannot dis-engage the clutch. The actuating arm moves, but the plates are not separated and therefore you have to roll the bike and kick it into first. On the move, the clutch action will return, but un-predictably. If you shift without the clutch, there is no slippage whatsoever so the springs and plates etc. are just fine. I am thinking that there is a wear problem with the ramp on the actuating arm, and or the push rod. I am sure all will be revealed over the weekend...

BTW, this problem just occurred without a gradual loss of performance. 1 week previous the bike did 4 AHRMA races without a single glitch.

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

you might have a bad clutch cable.the cable is stretching instead of dis engaging the clutch.does the clutch basket have excessive groves worn into the sides where the plates are?

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(2) 1968 DT1 1970 RT1M,1970 DT1C 1971 RT1B Enduro 1974 MT250 1974 DT250A (2) 1975 DT400B 1974 DT100,1978 DT175
1975 CR250M1 1979 CR250R 1979 Kawasaki KZ400H1 Jesus is Lord!!

The problem is inside the engine. The clutch cable is moving the actuating arm just fine. I can't say whether I have tangs on the clutch basket, but it is not a case of the clutch releasing, but stiffly it is there appears to be no connection between the actuating arm and the clutch basket at all.

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

Michael, Sounds like the clutch plates are froze together. Only way to find out is pull the clutch cover and see whats going on. I would think if something is broke at the actuator arm on the inside you would notice a big difference in the pull on your hand lever when you pull the clutch in.
You'll know when you pull the clutch off and see if the push rod is moving in and out.
Keep us posted and good luck!!

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Garry Mainer
#33m (retired)
Honda Cr250r 1980
Honda Cr250r 1980
Yamaha TY250C 1976
Arctic Cat 650 H1 2007

Hi Michael,

I agree with Gary as your 4 races may have had a toll on your friction plates and if you pull apart you should see the issue immediately.

If it was your actuator arm or internals then you would feel the difference in your lever action.

Let us know what you find and more importantly did you get the new FOX arm mounted yet for any of these races.

I found a 81 CR 250 arm and ended up mounting this on the bike till I find a DG or repo Fox banana arm.

If you here of any others let me know I am prepared to pay well for a used banana arm.

Paul

I think I am the king of bad clutches. Not so much the fixing part as the ownership part.

I've had clutches fry and soak up oil/impossible to operate after sitting for a week. Also had moisture do me in but I doubt if your bike ever sees any rain.

One of my favorites I've had three times on bikes I've fixed. I think there was contributing factors like the previous owner had the adjustment screw so far it hit the case. This caused the actuator rod to bend/flex when I pulled in the clutch. In a spastic momment I made the same mistake but recognized it before I did any damage. What happens is: There is enough intention to push the clutch plates apart but not enough shove to get it to separate in the first place. Lots of the travel goes into flexing parts. Once it breaks loose it works even with a bent rod.

Rick

It looks like I had a combination of two problems; fitting a new MSR clutch lever threw my adjustment off down at the actuating arm, and the clutch plates look to be on their way out the door. Changed back to a stock clutch cable and will take up all the slack down at the case, not the handlebar. Also took the actuating arm out and thoroughly cleaned it. Ordered a Barnett clutch kit ready for the next AHRMA race.

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

How did you get the clutch arm out?

There is a screw on the right-hand side of the case, about half way down the housing for the actuator arm. When tightened, the screw bears into a groove on the arm to keep it in place. With the screw removed, the arm and spring simply come out upwards. Make sure the dirt that gathers around the arm does not fall into the hole. When you put the it back in, the arm needs to point towards the back of the engine. Then when you rotate it forward to pick up the clutch cable, it engages correctly with the push rod inside the engine.

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

So you dont have to remove any of the clutch parts. Something is wrong with mine then, I have tried prying lightly but no luck. The seal leaks, Chris

Correct. I sent you a message, but you probably need part 91206-329-000....

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

Are you going to race the Taft race in March? I plan on being there, look for 83r . Chris

Yep!

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF

Michael,

Were you using a MSR Raptor clutch lever / perch setup on your '79 CR250R? I have the stiff clutch from hell on my '79! I've tried adjustments at both the lever and the actuating arm on the engine, but it is still stiff. My '78 RM250C2 clutch is like butter compared to my CR. I've heard others say the Raptor setup is the way to go. I have a brand new OEM honda clutch cable installed, so thats not the problem. The clutch works fine, just stiff to disengage at the lever. Thanks for any advice...

The next time out I will be using the MSR Raptor lever and perch with the cable nipple in the most aggressive pull position. I have used this on someone else's CR250R, and my CR480R and like the extra pull. Also the lever can be positioned closer to the bar which suits my hands. I am swapping out the current Terry Cable for an OEM one. The Barnett stiffer springs I already use will be joined by Barnett plates. The clutch basket has some minor tangs, but I am loathe to replace it yet. My instinct tells me this will be as good as it gets without a new basket. The action will be good, but always be a little "stiff" in comparison with the Maguras I have on my more modern bikes. C'est la vie.

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Michael Stiles
1979 Honda CR250R Elsinore | 2006 Husqvarna SM510R | 2007 Service Honda CR500R-AF