1986 Honda CR 500

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timva

Member

Jul 8, 2005

4

0

• Jul 8, 2005

• #1

I recently bought a running 1986 Honda CR 500, but on the first ride, The clutch went out on me. I took the flywheel cover off, which exposed the clutch lever. The clutch lever is really easy to move buy hand. The cable is moving freely, so I know it's not that, but if anyone has any suggestions, I would appreciate the help.

 

W

wornknobby

Member

Feb 5, 2004

625

0

• Jul 8, 2005

• #2

how are the springs? are they putting any tension on the pressure plate, i would check this first

 

R

Ruff Rider

Member

Sep 14, 2004

195

0

• Jul 8, 2005

• #3

how sure are u that its the clutch itself...sometimes by using/changeing gear oil will make a big diffence (if the problem was sporatic function or not 'grabbing')

If it doesnt work at all then its probily something else

Good Luck

 

T

timva

Member

Jul 8, 2005

4

0

• Jul 8, 2005

• Thread starter
• #4

I haven't taken the crankcase cover off yet. I intend to change the oil in it asap, but right now there seems to be no tension on the clutch lever. I can move the clutch lever through it's full range of motion without any resistance. It doesn't feel like I'm getting any tension from the pressureplate. I'm going to remove the cover tomorrow and see if I can see anything out of the ordinary. Any suggestions on what I should look for?

 

R

Ruff Rider

Member

Sep 14, 2004

195

0

• Jul 8, 2005

• #5

Did u try to work with the cable adjuster or maybe check at the arm right ontop of the case to see if its got too much slack

 

K

KX04

Member

May 29, 2005

68

0

• Jul 9, 2005

• #6

that happend to my friends bike on his the nut holding the clutch hub on backed off and was not tite we tightend that right up and it works perfect

 

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timva

Member

Jul 8, 2005

4

0

• Jul 10, 2005

• Thread starter
• #7

I took the crankcase cover off and checked the nut holding the clutch hub on. It was tight. I went ahead and removed it. I noticed that there was some type of a pushrod coming from the center the clutch spindle. When I pulled the clutch, the pushrod would move out, not much only about 1/8 to 1/4 inch. I put the pressure plate back on and I noticed that the pushrod was not contacting the pressure plate. I removed the pushrod and welded a 1/8" thick bead on the end of the rod. When I put everything back together, it worked perfect. I put the crankcase cover back on and rode the bike. About ten minutes of riding and the clutch began to act funny. It felt exactly like it had before. It feels like the pushrod is nolonger coming in contact with the pressure plate. No amount of adjusting the cable helps. There is fresh oil in it also. If anyone has any ideas, I would more than welcome them. Thanks

 

ellandoh

dismount art student

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Mi. Trail Riders

Aug 29, 2004

2,958

0

• Jul 10, 2005

• #8

there is a bearing in there on my old 88 cr250. it is a single sphere a little larger than a BB.
you probably wore out the bead you welded on there with the 1000's of rpm

goto your local fastenall store and have them get a bearing to match the thickness of the pushrod, when putting back together the bearing goes in firstthen the rod. also take off the left side cover and make sure the actuator arm is unobstructed

 

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timva

Member

Jul 8, 2005

4

0

• Jul 10, 2005

• Thread starter
• #9

What sucks is that I'm going to have to pull the whole engine to split the case on the left side, so that I can get to the acuator arm.

 

ellandoh

dismount art student

~SPONSOR~

Mi. Trail Riders

Aug 29, 2004

2,958

0

• Jul 10, 2005

• #10

its in with the flywheel, no case splitting necessary
it is just a thought if the bb isnt working

the straight pin that you welded onto sometimes wears down a new one on my cr250 was less than 1mm longer and made a big difference for 12.00$