[Buddy]

We need help. My son has a 2005 CRF250R. We replaced the inner basket, the Clutch Lifter Lever, the Clutch Lifter Rod, the Clutch Lifter, the 7 Steel Plates, the 8 Friction Plates, the Pressure Plate, and the Springs. After torquing the bolts and springs, the Clutch Lifter travels to far and does not push on the pressure plate before the Clutch Lifter Lever bottoms out against the clutch cable stop on the crank case cover.

[JimDirt]

Welcome to the site !!

I am wondering , are you using a aftermarket clutch cable as opposed to OEM ??? , I have had issues with some Motion Pro clutch cables where they were slightly too long , and I could not adjust it for the life of me , I also had a issue with a Motion Pro Throttle cable where the housing was too thick and it would bind up when you tightened down the gas tank , no matter how I routed it , it would bind up and make the throttle stick .... ever since then I have always bought OEM Honda Cables for clutch and throttle , so I know they fit right ...

[Buddy]

Not sure about the cables. I think they are OEM, I will take a closer look. It seems like the actuator is traveling about 1/2" to far. The lifter rod is not traveling far enough to lift the pressure plate.

[JimDirt]

Does the Clutch Lifter look OK ??? , is the needle bearing and washer and a little stopper ring (C-Clip)there , and in good working order ?? , and I am hoping you put it on the back side of the Pressure Plate correct ??

I just looked in my Factory Service Manual for it , and I could not find any measurements/specs for the rod . all it says is if it looks damaged or excessively worn , to replace ... same goes for the lever and lifter , but nothing about the actual length or specific specs for them ....

I am wondering if the lever is seated all the way ?? .... also , can you pull it and measure it against the old one and see if there is any difference ??? , and what was the reason you replaced them in the first place ??? , usually they last forever , I have seen baskets destroyed and grooved and worn and wobbly , and the lifter and rod and lever are usually still fine

[Buddy]

Yes Sir we actually replaced the lifter. It is installed on the back side of the pressure plate on the engine side of the plate. The bearing on the shaft that passes thru the outer basket look good. The bearing on the crankcase side where the actuator lever is located also look good. There is about a 1/2" of travel that allows the actuator to bottom out before lifting the pressure plate. The clutch disks, springs, and pressure plate bolts came from Moto Sport as a kit. It almost seems as if the plates are to thick. We removed the old disks and counted 7 and 8 steel to friction. The old plates and springs were out of speck. We put back the same number of plates back and replaced the pressure plate, springs, and bolts. Still at a loss. Thanks for trying to help.

[Buddy]

Is it possible that engine is on the line for what year it was manufactured and the 2004 or the 2006 clutch lifter rod is longer?

[Buddy]

I have notice that the Main Shaft and Bearing under the clutch basket moves out each time we torque the Pressure plate bolts. Is there anyway to fix this without splitting the cases?

[JimDirt]

Is it possible that engine is on the line for what year it was manufactured and the 2004 or the 2006 clutch lifter rod is longer?

I just checked the parts fiche and it is the same rod/part # from 04-10 , I did not check farther than that as it would be irrelevant

[JimDirt]

I have notice that the Main Shaft and Bearing under the clutch basket moves out each time we torque the Pressure plate bolts. Is there anyway to fix this without splitting the cases?

Are you sure the inner basket is seated all the way ??? .... nothing should move in/out

For the sake of trying it , reinstall the OLD parts and see what it does ...

[Buddy]

Sorry for the late reply. It appears that the main shaft bearing moves when the clutch basket nut is torqued. I think we are going to have to split the cases and replace that bearing and race. Has anyone ever seen this problem?

[JimDirt]

Now the clutch functioned fine before switching out everything right ???

I have not heard of that being a wear item in the sense of it not lasting the life of the bike , so if you grab the basket , it actually pulls out a bit ?? , if so that would definitely make it so the rod would not be able to push on the lifter ..... but I can't figure how removing the basket would change anything , so if it was ok before , it should be ok now , but I do not recall any endplay

Did you try the old parts like I mentioned to eliminate any fitment issues ?? if it worked before , there has to be something different , and for the most part , the parts should be the same from 04-09 , as that is what the Factory Service Manual I have covers