QuestionMike, I have 2 1978 Honda XL 125 with 1400 miles on it. It was in storage 19 years. I ran it for 400 miles with no problems. Recently the clutch does not engage when the lever is pulled and the bike lurches/quits when put in gear. Sometimes even in neutral it wouldn't roll until I went back and forth and something "unlocked" and it would roll freely. I put a new cable on, and I have a Clymer manual and have opened the case but don't know what to look for. Any suggestions would be appreciated.
Steve
AnswerHi Steve,
Q: "...Mike, I have 2 1978 Honda XL 125 with 1400 miles on it. It was in storage 19 years. I ran it for 400 miles with no problems. Recently the clutch does not engage when the lever is pulled and the bike lurches/quits when put in gear. Sometimes even in neutral it wouldn't roll until I went back and forth and something "unlocked" and it would roll freely. I put a new cable on, and I have a Clymer manual and have opened the case but don't know what to look for. Any suggestions would be appreciated. Steve..."
A: If the problem isn't obvious, precision measurements may be necessary to find the cause of the problem. Do you have plasti-gauge, micrometers, and dial indicators? If so, follow the service manual's procedures for inspecting parts for wear, true, and defects.
I would start by checking clutch plates for wear and warpage. Measure clutch spring free length and tension, if possible.
If the clutch checks ok, move on to the transmission and crankshaft.
I recommend having a professional tech inspect the problem for you. This is not easy work for the inexperienced and may cost much more to correct mistakes.
Respectfully,
Mark Shively
