Clutch im stumped 200x

[jenndnn3]

Ok I have a clutch when shifted into gear will not disengage, when lever is pulled in. I have checked and miced the plates, but my gut tells me it is not that. The spring are fine as well In fact everything looks great, or specs fine. But the clutch will not disengage. I have 3 clutches I have swapped around. I have searched, and some say run trike, until the plates release a little , but I cannot do that because it is a fresh engine, and I need the clutch to pull start. I need some quick places to check, something to point me where to look. Oh yes lever works we adjusted both ways. The lever pulls the little lever on engine just fine. Just tell me what I may be missing or what else to check. I am so close, to firing this thing, I got a pop and a backfire. But I cannot check why so hard to start until I have it running. Ie Jetting and all that other good stuff. So basically I really really need my clutch. Thank you Jen

[Huffa]

Your clutch basket is grooved. What happens is the friction plates tabs that slide on to basket put constant pressure on the basket and eventually where grooves in the basket.

Eventually these grooves get so deep that they will not let the disc slide back and fourth freely. You can take the basket off and file each groove smooth again unless they are too deep then of course you need a new basket.

#1 on here is the clutch basket. The "fingers" are what gets the grooves in them.

Once on link, click on pic to enlarge.

http://houseofmotorcycles.bikebandit.com/partsbandit/assets/schematics/Honda/H00930009.gif

[jenndnn3]

Hey Huffa, thank you, I have thought of that, I have 3 of those, What are the odds all 3 of them that way.

[Howdy]

Hey Huffa, thank you, I have thought of that, I have 3 of those, What are the odds all 3 of them that way.

Good odds! I know I have more than 3 that way for the 350x's. ;)
Howdy

[jenndnn3]

Is there a way I can mic for the best one to file? Or a mic number so I can see if they are all to far gone?

[Howdy]

Check the distance between the fins on the baskets you have. File the one that has the smallest space. ;)
Howdy

[Dirtcrasher]

I once ran into an RM125 motor that no matter what the clutch plates would not work. I could not figure it out. So, I took out all the plates and assembled the inner and outer baskets in the bike. When I tightened the nut for the inner basket it "locked" the outer basket to it. Of course I figure a thrust washer was left out or something but all the washers were in place and what happened was one of the shoulders - either in the aluminum basket or in the tranny shaft had worn out and allowed these 2 normally free spinning assemblies to lock to each other. I backed off that nut a half turn until the inner basket was free and folded over the lock washer and then it worked fine. I'm sure something could have used a few thousandths shaved off of it or a thinner thrust washer to fix it but thats what I was advised to do. Had I never assembled it without the plates I wouldn't have been able to see the problem. Just something you could check....

[kilabeez0]

I think someone just posted pictures of their grooved clutch basket a couple days ago, along with symptoms. you might want to check that out.

[KASEY]

even with a grooved basket the clutch will release ,,, if youe clutch linkage is all in good shape and you are getting the proper amount of travel it should releaseespecially if its all a fresh install correctly,,,,,,,,,

[jenndnn3]

Ok no go guys, more sugestions? I am still stumped. Dirtcrasher I tried yours right off, we filed, I looked over everything for warp-age. Lever works. With none of the bolts installed it will push the side cover up, so I know that is working. Springs? what can I check?

[KASEY]

if the clutch mechanizm is lifting the side cover AND has the proper amount of travel ,,,,,,your clutch is put together wrong or something is bound up,,,,

[Dads]

Check the clutch shaft for wear. were the shaft and pin come in contact the edge wears down and you loose clearance. (lessens through of clutch.

[jenndnn3]

Today is the last time I pull it apart, If we dont get it today I will send it in. And learn something new. Everything is installed correctly. I talked to Dads this morn via aol and I will be specing that shaft to my other 2. I am well aware something is bound up, but the question is "what" could be bound up? LOL I even change washers around, and mic those. As soon as I know what I have done wrong I will let you all know.

Thank you everyone for the help!

[atczack]

Jenn,

Same thing happened to me on my '83 200x the last couple of time's I've changed the clutch. I could pull the clutch in all the way but couldn't kick start it because it was still in gear. I hooked it behind my four wheeler and had my friend pull start me anyway. It started right up and something free'd up inside the clutch basket or aligned properly and the clutch worked perfectly afterword's. By the way, I don't mean any offense to Kasey, but when you undid the bolt's on your clutch case and pulled the lever and your case popped up a little, that IS supposed to happen. Because when you have the case bolted down right and pull the lever it pushes in on the clutch basket's four spring's. I say don't be afraid to pull start it, it has worked for me...

[jenndnn3]

We did but, the tranny really grinded, so my hubby refuses to do that. We tried twice. It is a fresh tranny which is more important to me then that clutch.

[kilabeez0]

well since your still stuck i'll throw out a small suggestion. When I rebuilt mine, I was having a clutch engaging problem, I forget the actual symptoms but everything "seemed" correctly installed. The little lever that pulls back and forth on top of the case, well the rod that that is connected to inside the case has a little spring on it. The ends of the spring have little hooks on them that grab onto little nipples. I cant remember exactly what happened with mine, but I know the spring wasn't grabbing correctly. I had to cut part of it off, bend the ends, and kind of fab it up in order to work correctly. Just an idea. Good luck Jenn!

[bakeban]

i rebuilt my motor on my x and i had a clutch problem where the motor would start and when i put it in gear it wouldnt go. the clutch would not release enough for it to pull itself and when i put it in gear it wouldnt let me take it back out. when the motor was stoped it would shift alright. i tried a couple of clutches but they didnt worlk. on friday i got pissed and took the motor back apart and i noticed that the thrust washer on the kickstarter gear of the input shaft(the fat one that the clutch goes to) was crushed and had bound it up. today i am going to set the motor back in and see if that works. maybe you have the same thing wrong with yours as i do. good luck

[bakeban]

i got the motor back in and it works. i would say check that thrust washer.

[jenndnn3]

We know what it is, we think. I had my neighbor over, we went through everything thoroughly. Ok I learned a ton of stuff today. But I will tell you it was a real dumb mistake on my part. And one not caught unless my neighbaor had not been here. By the way every piece is where it belongs. There truley is only a couple of thing that would cause this. So we backed tracked. We are looking for disengagement. Now mind I will give you 24 hours and after a backyard puller is made to see if we are correct on what the problem is. Hopefully the puller will work or else. Anyway here are some clues as to what i messed up on....
It is not the shaft in the cover,
It is not any form of the clutch whatsoever
I have a free flowing kicker and gears.
I have idle.
So what is suppossed to free flow and is bound up, because I didnt double check to see if it was in all the way that would require a puller...

By the way we got her started,, she is neat sounding....

[bakeban]

one of the case bearings perhaps?

[bigredhead]

nothing to do with having an XR 6 speed gears in there.

[kilabeez0]

magneto/flywheel....keyway?

[jenndnn3]

It was without a doubt the bearing. For what ever reason it wont seat. We pulled it and put the old one back in. So yeah we had to split. But we also ended up swapping out the idler gear as well..

[caleb200x]

My 83' 200x's clutch has been giving me problems for some time now, i have put 4 sets of clutch plates in, then it will work fine for about 3 hours or so , then it will start slipping again and go out. Any suggestioins on whats going on will help tremendously. THANKS