QuestionI am doing my first rebuild of a Honda 125XL. When I purchased the bike the Clutch would not shift. I am in the process of checking things out internally but before I even get started on that I noticed that the clutch assembly where the cable hooks in on the outside of the crankcase is was seized up. I have used a mallet to loosen it up a little but it still is very hard to move either direction and it definitely doesn't spring back into place. Maybe the shaft that goes into the crankcase is a little bent or maybe it has rusted more on the outside and that is the problem.
What is the best way to either pull the lever out without damaging the crankcase? I pulled the cotter pin out at the end of the shaft but the assembly is not going to move out easily and I don't want to damage anything else. Is there a trick or simple way of pulling this out? Also once it is out what is the best way to lubricate it or prep it to go back in?
Thanks for your help.
Best Regards,
Tyler
AnswerWHOA, Tyler! You are addressing the symptoms, NOT the cause!
The reason the clutch release arm is stuck is because the bike was sitting for a long time and the clutch plates are all stuck together inside. NO MORE HAMMERING, unless it is with an impact driver to help you get the case screws out.
Pull the footpegs and exhaust system, so you can access the case screws. Get an impact driver with a LONG #3 bit to use on the screws. Use the bit, first, like a long punch and place it into the screw heads, smack it a couple times with a small hammer, then install the bit on the impact driver and loosen them up for removal. The screws probably have never been removed before and they have had electrolysis build up between the steel screws and the aluminum cases. Have some KROIL or SEAFOAM penetrants handy to keep soaking the screws as you remove them.
You may need the mallet to work the clutch cover loose, then you can take a look inside of the case, where the release lever is and be sure you didn't damage anything.
You can remove the shaft now that the cotter pin is out, so tap things apart to see if there is corrosion or damage present.
Next, pull the 4 10mm (head) bolts from the clutch pressure plate assembly and pry the parts loose, noting the order of the steel and fiber plates, separating them and clean anything reusable as you go. Get a new gasket for the cover and a new seal for the shafts coming through the case cover. The hardest part will be getting the gasket material off the cover and engine cases, so get good gasket scrapers, single-edge razor blades, etc for the job. Stuff some rags inside the case, to prevent gasket material from getting inside the motor. I believe that there is a small oil filter screen stuck sideways in the crankcase, which can be removed and cleaned, while you are in there.
Repair manuals are available from Honda at www.helminc.com or usually from various sources on Ebay.
Bill Silver
