Question1976 Honda CB125S the motorcycle sat outside for a number of years without running. the clutch is stuck and won't disengage when handle is squeezed. how do you repair or replace it? Is there an online manual where I could see a diagram of the clutch?
AnswerLee, buy a new gasket and seal for the clutch cover first.
Remove the exhaust pipe and footpegs, as I recall....
USE an impact driver to loosen the screws!
Use a soft mallet to loosen the clutch cover case.
There are 4 bolts that hold the clutch assy together. Loosen each a few turns at a time, then remove the outer clutch cover plate. The clutch pack will probably come out as a block. Note the position and sequence of the plates... fiber, steel, fiber, steel...etc. Gently peel the stack apart, inspecting each part. Sand the residual clutch material/rust from each of the steel plates and check them for flatness on a piece of glass or other flat surface. Replace warped plates and scored/worn plates.
The clutch fiber plates will probably be okay, but if the little lines are all worn off, then replace them. Clean EVERYTHING with solvent and lightly oil the plates as you reassemble them. Be sure that they are all tucked down in the outer clutch basket and there are no big gouges in the slotted areas of the inner and outer clutch hubs.
Scrape all of the gasket material off carefully with a gasket scraper or single edge razor blade... take your time and don't gouge the cover or the cases. Replace the cover seal and then install a new gasket. You don't have to use sealer on these parts, if everything has been cleaned properly.
Reinstall exhaust, pegs etc. Adjust the clutch for a little free play at the clutch lever and you are off and running again.
Bill Silver
