CG125 Clutch Problem..

[Keith]

Hey everyone.

I bought a cheap winter hack (Honda CG125 1990 Brazil model) off ebay for £210 so I obviously wasnt expecting much for my money. Apart from all the rust, the bike is in pretty good condition and the engine runs perfect except a clutch problem.

Basically, when I pull the clutch in and put it in gear, it stalls.

The cable itself is fine so its obviously an internal problem.

What I'd like to know - What are the possibilities of the problem?

I think it could be the plates sticking together, or buggered springs, but I'd like your input. Also whats the price range I'm looking at to repair. (If it needs it)

Hope you can help, and thanks in advance for replies.
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Aprilia RSV Mille R Edwards Replica - Aprilia RS250 - Suzuki GSXR600 Supersport Race Bike

[stinkwheel]

Stick it in gear with the engine off and push it forwards with the clutch pulled in. Is it turning the engine over?

If it isn't, the clutch isn't the problem. Check for any safety interlock switches on the sidestand and clutch lever that may be malfunctioning.

If it is, either the clutch isn't disengaging or the plates are stuck together. If you start the engine, hold the clutch in and the back brake on and knock it into gear, after a few stalls, stuck plates should free off.

Otherwise there is probably something wrong with the clutch mechanism itself.

First off I would check the cam and pushrod that presses the clutch plates apart, this is the bit on the inside of the left hand cover where the cable attaches to the lever on the crankcase cover. If you take this cover off, you should see a mechanism attached to the inside of it that moves in and out (only a small distance) on a kind of screw when you move the clutch lever. This pushes a long metal rod that goes right through the engine and bears against the clutch itself. When you pull the lever the screw moves out, pushes on the rod which in turn pushes against the outermost part of the clutch causing the plates (which are held together with springs) to move apart slightly thus disengaging the clutch.

If this mechanism is faulty, it should prove obvious. The rod could also be bent or indeed missing if you have been sold a lemon. On some bikes this rod is one piece, on others it is in two pieces with a small ball bearing between the two (right in the middle of the engine) this could be missing.

If everything looks ok from that end, you will need to have a look at the clutch itself. This involves draining the oil and removing the right hand side cover. You will see the clutch looking at you, unscrew the circle of bolts that hold the clutch springs in, put them to one side then slide the clutch plates out of the basket. If they are well stuck together, you have found your problem, seperate them by hand, give 'em a wipe, maybe even a clean off with some WD40 and lightly oil them.

Again, it should be pretty obvious if there is anything else wrong in here. You also now have access to the other end of the push rod, it should pull out from this end...watch out for that ball bearing (not sure if a CG has one). If it all looks OK, reassemble, refill with oil, adjust the cable and see if that has fixed it. You might as well clean the oil filter whilst you are in there.

This is not a big or difficult job, the only really tricky bit is getting the cover bolts out, you may well need an impact driver, WD40 and a fair bit of patience. The clutch plates can be a fiddle to get lined up when you are reassembling it, but it is just a case of fiddling 'till everything slots home

As everyone harps on about...a workshop manual will prove invaluable.

hth
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Keith]

Thanks for the help.

I'll have a fiddle around with it this weekend, hopefully its just stuck plates from standing for a while.

Information is much appreciated.
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Aprilia RSV Mille R Edwards Replica - Aprilia RS250 - Suzuki GSXR600 Supersport Race Bike

[pipnet11]

The safety engine kill switches are far more likely to be nackered than the clutch. Do what stink wheel says, pushing it with the clutch in and it in gear can rule the clutch out as a problem in seconds.

If you do find that its the switches, and you dont think you'll leave the side stand down/never use it, just twist the ends of the wires together, that was my solution anyway. Dont think it would get through a MOT like this though

Phill
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I love the girls that do, I hate the girls that dont, I hate the girls who say they will and then they say they wont, but the girl I like most of all and I think youll say Im right, is the girl who says she never has but looks as though she might. - Max Bygraves

[Keith]

[mchaggis]

[paulodd]