cr500 clutch mod/ hard lever pull

[FloridaRiderSG]

Hey fellas, hope all has been well.

I always had a hard pull but after a couple rides it felt like the clutch wasnt disengaging all the way and it went into gear hard. Havent rode it since, got a 450f and been riding 2 wheels. Im going to sell my R but wanted to see what was going on with the clutch, took it apart, lever/cable free pull, then I pulled the pressure plate off and the thrust washer/bearing washer was on the inside of the shaft bouncing around. I corrected that, put them between the clutch rod and pressure plate but it still pulls hard. Now I didnt build the motor so I dont know if he did the cr500 mod but I did notice the clutch spacers are all dimpled. Now in the videos I see the 250r spacers dont have dimples and the 400ex does, do you guys know if this is true or do some 250r spacers come with them also? I used a micrometer and the measured 1.5mm as to what the 250rs should and the 400ex should be 2mm, I have a 400ex spacer coming so I can check them next to each other but I want to make sure it doesnt have all 400ex spacers.

btw I didnt pull the motor and it sucks scraping gaskets off like this!!

[croat1]

Here’s some good info:

https://www.forums.trx250r.org/index.php/topic,2775.0.html

Joe

[FloridaRiderSG]

Many thanks. I had found thread with a little less info then that but then never could find it again. Appreciate it.

[FloridaRiderSG]

From the pictures it seems like I have a much bigger gap between the basket nut and the piece (sorry exploded view doesnt have that part listed) that the thrust washer goes on. Ill try to get a picture up.

[FloridaRiderSG]

Also the extra thrust washer goes between the needle bearing and the pressure plate? I think it would make sense to have the bearing up against the pressure plate?

[4WHLr]

Yes, the thrust washer goes between the pressure plate and the bearing so the needle bearings don't ride on the aluminum. 

[4WHLr]

The old diagrams didn't even show the pressure plate thrust washer in them if i recall, just the bearing.  This setup was for 1989 only
There should be a machined cut out in the pressure plate for the washer to sit in if you have the correct pressure plate, to run that 89 throw out bearing set up.

[FloridaRiderSG]

Excellent. Yes it does have a groove, thought that was there because it wasnt together correctly the first time. Thanks!

[FloridaRiderSG]

Also just putting it out there Im looking for a radiator hose from head to water pump, cant believe mine didnt pop, it was burned al the way through until it was soft like a balloon.

[FloridaRiderSG]

Put everything back together and its not engaging. does the inside of the pressure plate look right?

[croat1]

Put everything back together and its not engaging. does the inside of the pressure plate look right?

If you can please get a pic of the washer by itself.

Joe

[FloridaRiderSG]

ok this is the washer.

Now going back when I first took the clutch apart that washer was not in the correct spot, it was on the wrong side of the pressure plate/shaft. Now when I add the washer it creates a space in my clutch pack, I take it out and its tight. So I guess this is why the guy who built it had the washer just free floating.

Any ideas on why the washer would create this space? Im going to check the thickness on my fibers, not sure if they are the reason.

[FloridaRiderSG]

Im thinking its missing the thrust washer behind the basket, going to take it apart and see if its in.

[FloridaRiderSG]

I removed the center clutch and there was a thrust washer behind it but it looked a little grooved, probably should be because the pressure plate was also but Ill post a couple pics to just make sure.

[4WHLr]

Can you also post a picture of the clutch lifter? The piece on the end of the clutch rod that the needle bearing goes over.

I see the needle bearing, but is there also a steel washer in the center of the  pressure plate? kind of hard to tell in the pic.

also, is the clutch arm in its correct position, with no cable input?