Honda CR250 1999 Clutch inner hub not spinning.

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Sandblaster
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Honda CR250 1999 Clutch inner hub not spinning.

Post by Sandblaster » Wed Apr 17, 2013 7:50 pm

A customer came in with a 1999 CR250 and the inner clutch hub was not spinning after the nut was torqued to spec.
If he backed the nut off a little the inner hub would spin freely.
A quick inspection did not reveal anything that looked like a problem.
So I went to a few other web forums trying to glean some information.
I even called a certified Honda mechanic.
I could not believe some of the answers I received.
The Honda mechanic told me that he just backs the nut off until the inner hub spins and then he folds the set tabs over :o
So we looked a little harder and found that the small gear on the back of the clutch basket stuck out away from the back of the basket.
This is what a good basket was measured at:
99 CR250 CLUTCH BASKET -1.JPG
99 CR250 CLUTCH BASKET -1.JPG (27.12 KiB) Viewed 1255 times
I could not find any specs for this in the Clymer Service Manual.
But as you can see ours measured .3995" or 10.15mm.
The customers measured 0.4232" or 10.75mm.
So, the customer is going to press his gear back to our measurements.
He will support the basket by the steel rivets and press it from the small gear on the back

Support from this side on the steel rivets.
99 CR250 CLUTCH BASKET -2.JPG
99 CR250 CLUTCH BASKET -2.JPG (18.2 KiB) Viewed 1255 times
He will press from this side on the gear with a block of wood to keep from marring the gear face surface.
99 CR250 CLUTCH BASKET -3.JPG
99 CR250 CLUTCH BASKET -3.JPG (22.4 KiB) Viewed 1254 times
I will let you know if this works.
If bikes are for kids I'll never grow up.

User avatar
Sandblaster
Posts: 5246
Joined: Thu Jun 07, 2012 3:50 pm
Location: Eugene, OR
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Re: Honda CR250 1999 Clutch inner hub not spinning.

Post by Sandblaster » Sat Jul 01, 2017 4:19 am

Problem solved :-)
If bikes are for kids I'll never grow up.

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