CR125 clutch lever

Ray Lovestead · Posted: Tue Oct 23, 2012 2:37 pm Post subject: CR125 clutch lever

Curious - my clutch lever takes Herculean levels of strength to pull. I've replaced pretty much everything (clutch cable, clutch springs, clutch plates, etc.) and it still I have to get angry and green to pull the lever.

"Hulk Angry!"

Another question. When I pull said lever, I'd expect the kart to coast along easy like. But it doesn't seem to pull the clutch plates apart as much as it should to let it run free. Anyone else see this?

Thanks!

Ray
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Vernon Head · Posted: Tue Oct 23, 2012 9:40 pm Post subject:

Yes, when you pull the clutch lever you are still going to get some drag from the the plates and the kart will not roll freely unless in neutral.

Roger Miller · Posted: Tue Oct 23, 2012 9:50 pm Post subject:

Several things to check - first of all, no tight bends in the cable. Including right at the steering column and the clutch lever connection.

Then, make sure the stator tab that locates the clutch lifter lever that the cable is connected to in the engine is keeping the lifter lever fully into the hole it fits into. We had a problem where the tab didn't hold it in all the way and that made the clutch hard to operate. It also ended up damaging all of the parts in the clutch release circuit.

Starting at the lever and the cable, it pushes on the end of a long rod that goes through the center of the shaft for the clutch assembly and traverses from the left side of the engine over to the right side, and there is a ball bearing - a single ball - and it fits against a top hat looking thing that actually lifts the clutch cover thing.

We had the little lever, the shaft and the ball all show damage and galling from it being hose up. Replaced all the parts, and then pushed on that tab on the stator to get it to really fit against the lever and all was good.

Unfortunately the Honda parts pictures don't show the tab on the stator backing plate very well, but you will see it near the lifter lever when you look in there.

Parts 8, 10, and 20 in this picture:

And #11 in this picture, it goes into the hole sorta behind #27:

Ray Lovestead · Posted: Wed Oct 24, 2012 9:20 am Post subject:

Thanks Roger,

I've got my engine all in pieces now, so I'll inspect those parts tonight. It may be possible that I'm missing the washer directly below the locking washer.

I've got a newly installed Swedetech clutch cable - with no kinks or tight radii. Do you find that it requires a lot of strength to pull the clutch?

On a motorcycle, pulling a clutch is a casual affair. On this kart it seems to take way more strength than it should.

Ray
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Greg Wright · Posted: Wed Oct 24, 2012 10:46 am Post subject:

The clutch pull is a bit stouter than most motorcycles but it shouldn't require tons of strength.
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Roger Miller · Posted: Wed Oct 24, 2012 10:48 am Post subject:

Actually, once we got it sorted, it is quite easy to pull, like "buttah" compared to when it wasn't working right. We sort of chased it a bit until we found the issue. Probably a no brainer for some, but it was weird to us and took a bit to find. Mostly because the engine is so tight with the seat it wasn't easy to see the problem until the engine was off and then we noticed the lever sliding in and out of the seal by a good bit. That was when we starting looking at the individual parts and saw the notched end of the lifting lever was chewed up.

Todd Kageals · Joined: 15 Jun 2012 Posts: 271

I have the same issue on my '94 CR125 and I have the swedetech cable too. I recently took the clutch out and discovered that it's not stock. Says something line "Billett Racing" or something like that on it so I am assuming that's why it's so hard to pull.

Chris Reinhardt · Posted: Thu Nov 08, 2012 6:35 am Post subject:

Todd, the clutch plates and or the basket won't change the pull much, but the springs will. I haven't found a spring I like better than the OEM Honda springs.
I would put all your plates back in with a set of stock Honda springs, should be good to go...

CR
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