Need help on my CR!!!

[Toddco327]

I’m trying to get this thing going. When I bought it the guy said “the clutch cable is broken”. Well as I’m diving into it I see they broke a bolt in the clutch hub. Ordered a new hub. Put it in. And then now when I put it all back together the clutch won’t engage.

My question is… On a 2004 cr125 is there a ball bearing that goes between the clutch shaft and the little top hat that makes contact with the clutch plate?

 

[NQ1965]

Doesn't appear to according to the parts breakdown.

 

[Toddco327]

Based off the specs the rod I have is the correct length. And yes I see that the parts list doesn’t show it. But in the past I’ve ran into things not being on the diagram.

The manual is zero help too.

 

[MarctheSharc]

Engage or disengage ?
The clutch is always engaged - pulling on the cable disenages it. (opens it up)

 

[Toddco327]

pulling the lever will not disengage it.

the arm moves and so does the push rod. But not the total distance needed

 

[MX955]

Is the arm that moves the rod wore out where it pushes on the rod? I’ve seen this on older YZ’s and it doesn’t disengage the clutch

 

[MarctheSharc]

Yep, Check the push lever.
Make sure it's properly seated in the case and check to see if it's cam may be worn out.

 

[MarctheSharc]

There is a small tab on the cases that hold the push lever in the proper place.
If this tab is bent or broken it will allow the push lever to move enough inside the bore to not make the push rod move full travel.

 

[MarctheSharc]

I stole this pic from a different topic so ....- it has nothing to do with the yellow circle.
It's just you can see the tab in this pic.

 

[TwentyThreeMX]

is the little ball in there behind the push rod? i'm pretty sure that happened to me once, that ball dropped out when i took it apart and didnt realize it was even there. #1 in ur diagram

 

[MarctheSharc]

#1 is the circlip that holds the washer & bearing onto the top hat (clutch lifter)

 

[MarctheSharc]

hummm? - some sites are saying there's a ball?

 

[Toddco327]

is the little ball in there behind the push rod? i'm pretty sure that happened to me once, that ball dropped out when i took it apart and didnt realize it was even there. #1 in ur diagram

that’s kind of what me and MX724 were thinking that there was a ball in there. When I took it all apart there was no ball.
So last night I took a BB and put it in just for a test and it then seemed to work perfect.

Yes #1 on the diagram is a C clip to hold the top hat together.

Push rod and the arm seem to be in good shape. I’ll post a pic of the actuator arm. Also the rod seems perfect to

And all the parts on the clutch are correct. The hub, basket, plates are all the right ones.

Anyone have a CR lying around and can let me know. I’ll throw you 20 bucks to take the clutch off lol.

 

[Toddco327]

hummm? - some sites are saying there's a ball?

Yes some have a small ball in there. Seems like the earlier models. But the push rod for the CR ranges from like 1987 to 2006.

Tab is also in the correct spot and not broke.

 

[Toddco327]

Some pics of the arm and the tab that holds it in place

 

[mxsk8r007]

Hi, I am a long time Honda tech. I am thinking the bottom end of your bike may be from pre 2000. I just looked in a factory service manual and CR125R from 1992-1999 show that there is the small ball between the rod and the lifter. This is also shown in the parts diagram. Other thing could be that the rod is from a pre 2000 bike? I own/ride a 2002 CR125 and it does not have the ball.

 

[TwentyThreeMX]

good call on the BB. I'm pretty sure the suzukis had the ball, and pretty sure i put one together without it and it behaved the same way. so thats probably it. and yeah i can see #1 now is the circlip, duh. looking at sharcs pic the ball is easier to see.

 

[Toddco327]

Hi, I am a long time Honda tech. I am thinking the bottom end of your bike may be from pre 2000. I just looked in a factory service manual and CR125R from 1992-1999 show that there is the small ball between the rod and the lifter. This is also shown in the parts diagram. Other thing could be that the rod is from a pre 2000 bike? I own/ride a 2002 CR125 and it does not have the ball.

Wow thank you so much!!!! I can’t imagine the motor is pre-2000 as everything else is 2004. The inner hub I bought is for a 2004. But it still could be a possibility since they said they rebuild the motor. If you don’t mind feel free to give me a call and I can pick your brain a little more.

Also the push rod looks the same but the top hat portion does look different.

440-503-2404

 

[MarctheSharc]

I don't think you have the ball (in a 2004 CR 125).
This is a 1997 CR 125 and it clearly shows the ball as an orderable part #20
I've got a hard time believing that the HONDA fiche all of sudden isn't including all the proper parts.

Plus, This is the old style top-hat (no bearing) that's part of the reason for the ball (to minimize the contact point )
You have the new style - with thrust bearing

 

[MarctheSharc]

Honda went to the new style top-hat with the bearing in 2000.
No more balls after that ....