clutch woes

[DeePa]

I bought a new cable for my 85 r...i installed it, put the bike in gear, pulled the clutch lever to put the bike away, and pushed the trike, but the wheels locked up, like the clutch was still engaged. I adjusted it to its max at both adjustments, and still nothing.

I dont get how it was fine before i took it apart, and now it acts like the clutch lever means nothing.

I put the old cable back on, adjusted it to where it was before, and still nothing.

Can you pull the clutch lever too far and have it engage the clutch again? Like how its at the max adjustments, the cable would travel too far and make the clutch engage again?

I just dont understand this. What can i do to fix this? How hard is a clutch on an r to change? I remember hearing about the clutch update thing from a newer trx250r, but i dont remember.

Please help me out here.

Thanks,
Mike

[Yamahauler]

If the bike is not running and its in gear, you can pull the clutch and it will still drag. Completly normal. I couldnt figure out why my Z did that, then someone told me its supposed to happen.

Start you bike up, pull the clutch and put it in first. It should be fine!

[DeePa]

i did, and it stalled out because of the clutch

anything else? all of my other bikes i can pull the cluch and start the bike in gear...i try it on this one, the bike moves forward

i dont get it

Thanks,
Mike

[Yamahauler]

Is the lever on the outside of the case ajusted properly?
You'll probably have to pop off the clutch cover and play around with the internal ajustment.
When you take it apart, make sure all of your linkages are in good shape and arent worn.
My pushrod that connects the lever to the pressure plate was worn right down becuase my adjuster screw had a bend in it. The clutch pull was hard as hell for a while, then it finally wore that pushlever down, and the clutch wouldnt disengage.

When you pull the clutch, can you feel the springs compress?

[DeePa]

yeah, i think so...theres a lot of resistance...actually i dont really know, ill have to check into that tomorrow...maybe ill pull it all apart, check everything, and reassemble as long as everything isnt worn.

Maybe thatll help it some.

Thanks, and keep those opinions comin haha,

Mike

[Yamahauler]

Check your basket for groves from the plates. They can get caught in them and not disengage.

You will probably see some grooves in it, take a file and make it flush. That way you know you dont have to worry about it!

[ChrisD]

The Honda clutch has a couple problem spots. If you're having trouble finding your "sweet spot" on your clutch it's most likely a worn "clutch release arm" (what your cable connects to on the motor) or as Yamahauler suggested, the pushrod assembly is bad. The ATC clutch pushrod had a ball bearing at the end of the shaft that wasn't a very good design. It can bind up, causing damage to the whole assembly. The 89 upgrade kit will relplace all of the affected parts except the clutch release arm.

Grooves in the basket are a likely contributor as well, but that ususally causes clutch slipping, not what you're describing.

I would get the 89 TRX clutch upgrade kit as well as the "clutch release arm" while it's apart. It will cost under $100 to fix it and you will be all set for the next 20 years. Also, as Yamahauler suggested, I would carefully file down the grooves in the basket while you have it apart.

[crackshot]

What years clutch baskets will fit an 85R?

[ChrisD]

85 or newer ATC or TRX baskets will fit.

[DeePa]

i finally got it all disassembled, and the plates look ok, the lifter and ball bearing are perfect, and the rod connecting the cable actuator is nice and straight, and the acutator is perfect. The basket had very small grooves which i filed nice and smooth. I think im going to do the update kit anyways, due to the fact that the clutch is still at the max adjustment.

I reassembled it, pulled the clutch, and pushed the bike and it moved. Not completely free, but it moved. I am goign to order a clutch kit somewhere, with stock springs, and grab that update kit.

Thanks for your help,
Mike

[crackshot]

i finally got it all disassembled, and the plates look ok, the lifter and ball bearing are perfect, and the rod connecting the cable actuator is nice and straight, and the acutator is perfect. The basket had very small grooves which i filed nice and smooth. I think im going to do the update kit anyways, due to the fact that the clutch is still at the max adjustment.

I reassembled it, pulled the clutch, and pushed the bike and it moved. Not completely free, but it moved. I am goign to order a clutch kit somewhere, with stock springs, and grab that update kit.

Thanks for your help,
Mike

Did you install a new gasket or use old one?

[max]

Is the lever on the outside of the case ajusted properly?
You'll probably have to pop off the clutch cover and play around with the internal ajustment.
When you take it apart, make sure all of your linkages are in good shape and arent worn.
My pushrod that connects the lever to the pressure plate was worn right down becuase my adjuster screw had a bend in it. The clutch pull was hard as hell for a while, then it finally wore that pushlever down, and the clutch wouldnt disengage.

When you pull the clutch, can you feel the springs compress?

Their are no internal adjustments.

[DeePa]

there are no gaskets installed yet...i just put the clutch basket, plates, and pressure plate back together to keep everything neat and organized. THe cover is still off. I have a new gasket. I just ordered the update kit, and i have to figure out good clutch friction plates and i may just get the steel plates and springs for the extra 10 bucks.

How is this deal on ebay?

http://cgi.ebay.com/ebaymotors/NEW-B...19772485QQrdZ1

or

http://cgi.ebay.com/ebaymotors/HONDA...11627898QQrdZ1

thanks,
mike

[Yamahauler]

Their are no internal adjustments.

Must be differant than a Z then. The Z has a adjuster rod and a lock nut.