Clutch problems -

[Kentknudsen92]

I have a 2003 Honda CR250 with about 25 hours on it total. I started racing Harescrambles, that are dead engine starts. Recently my clutch will not disengage enough to allow the bike to easily start in gear.

I have pulled my clutch apart and both springs and friction plates are within spec. (plates avg. were 2.94 - 2.97 mm). My clutch basket look new, no grooves at all. I have of course checked my lever free play and even with no free play I can't pull to fully disengage and start the bike in gear.

I have just a my left side crank case replaced due to a hole from a snapped chain. I am not sure if that could have anything to do with it, since the clutch rod run trhough it.

Any ideas and suggestions are highly appreciated.

 

[Faded]

I have just a my left side crank case replaced due to a hole from a snapped chain. I am not sure if that could have anything to do with it, since the clutch rod run trhough it.

Since the case is damaged make sure it isn't limiting the movement of the linkage arm (behind the ignition cover) that actuates the clutch rod. Also, make sure the clutch rod length is in spec.

 

[CR3999]

Had the same problen on my 01 CR, I race H-S also. I put a Hinson clutch basket in it after the old one was worn out ( inner and outer basket ) and it started first kick everytime. Until then I started the engine put the bike in gear blipped the throttle, killed the engine and held in on the clutch lever until the flag was raised. Good luck, it worked most of the time.

 

[Kentknudsen92]

Thanks guys for your suggestions. I had my dealer replace the case and expected they checked the linkage but this could very well be problem. When my chain hit the case it cracked and left the linkage exposed. I'll try to pull the rod to see if it is bent or out of spec. I wouldn't mind changing to a Hinson basket but would hate to spend the money if it doesn't fix my problem.
Thanks again.