May 6th, 2018, 02:08 PM | #1 |
ninjette.org newbie
Name: Zipporah
Location: LA
Join Date: Aug 2017 Motorcycle(s): 2007 Ninja 250 Posts: 5
|
Clutch engages but doesn’t disengage
I have a 2007 250 that I did an engine swap with from a donor bike. The original engine had a blown head gasket, but I was able to find 2 donor bikes for $400. Everything went fine with the engine swap, but after everything was put back together and I went to take it on a test ride, I noticed that the clutch wouldn’t disengage (cut power to the rear wheel). I decided to check out the clutch plates and they did look pretty scratched up so I switched them with another set thinking that would solve the problem. Nope! I’ve attached a picture of how the rough plates that I removed look.
Any ideas? I’ve tried adjusting the clutch on the engine side and at the handlebar and I can get it set to a good friction zone, but just no disengaging. |
|
May 6th, 2018, 03:50 PM | #2 |
ninjette.org certified postwhore
Name: AKA JacRyann
Location: Mesa, AZ
Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot.
MOTY - 2018, MOTM - Nov '17
|
Hi and welcome!
Please post photo of left lever with cable and clutch lever down at engine. Also the clutch springs and basket. Look down the wells/tunnel where the springs go and make sure someone hasn't shimmed it too much. This causes coil-bind before clutch-plates have disengaged. Also count total number of plates. The very last plate is slightly different? |
|
May 6th, 2018, 05:49 PM | #3 |
ninjette.org newbie
Name: Zipporah
Location: LA
Join Date: Aug 2017 Motorcycle(s): 2007 Ninja 250 Posts: 5
|
Here’s the pictures of the handlebar and engine side clutch. I’ll have to post the springs and basket photos tomorrow when I can break it open again. I did try every combo I could think of with the adjustments - fine adjuster all the way in/out and engine side clutch top/bottom
When you say shim, what do you mean by that? I do remember that the clutch spring bolts were different from the OEM bolts on the other stock engine I got the plates from so it wouldn’t surprise me if someone had been in the engine tinkering around. The plates “should” be the OEM plates. I took them out of the stock engine where the clutch was functioning and placed them in this one that had the scratched plates. I wonder if I should’ve also used the OEM springs and bolts also? Last futzed with by zjjdbd; May 6th, 2018 at 05:50 PM. Reason: More info |
|
May 6th, 2018, 06:47 PM | #4 |
ninjette.org certified postwhore
Name: Tom
Location: Northern Virginia
Join Date: Jul 2015 Motorcycle(s): 2001 Ninja 250, 2019 Harley Ultra Classic, 2001 Suzuki SV650 Posts: A lot.
MOTM - Jan '16
|
Pull your outer pressure plate and rotate it 90 degrees.
|
|
May 8th, 2018, 08:31 PM | #5 |
ninjette.org certified postwhore
Name: AKA JacRyann
Location: Mesa, AZ
Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot.
MOTY - 2018, MOTM - Nov '17
|
Make sure that sides of fingers in your clutch basket aren't notched like this. File them smooth so the discs can slide and separate.
Look down holes where springs sit and remove any washers or shims that may be down there. Or shims between bolts and springs. Remove those too. There should be only spring and bolt with captive washer. |
|
May 9th, 2018, 02:11 AM | #6 | |
ninjette.org certified postwhore
Name: Bill
Location: Port Huron, Michigan
Join Date: Mar 2017 Motorcycle(s): 2007 Kawasaki 250 Ninja, 1982 Honda Ascot FT500 Posts: A lot.
|
Quote:
Notes from the service manual; - "Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or it could slip into place later, creating enough cable play to prevent clutch disengagement." - Fit the spring plate back into place, aligning the mark on the plate with the mark on the clutch hub. - Visually inspect the fingers of the clutch housing where the tangs of the friction plates hit them. If they are badly worn or if there are grooves cut where the tangs hit, replace the housing. Also, replace the friction plate if their tangs are damaged Bill
__________________________________________________
Insanity: doing the same thing over and over again expecting different results each time. |
|
|
May 9th, 2018, 04:24 PM | #7 |
ninjette.org newbie
Name: Zipporah
Location: LA
Join Date: Aug 2017 Motorcycle(s): 2007 Ninja 250 Posts: 5
|
Finally got around to opening it up. Springs didn’t have any shims. And no visible notches that needed to filed down.
|
|
May 9th, 2018, 05:40 PM | #8 | |
ninjette.org certified postwhore
Name: Bill
Location: Port Huron, Michigan
Join Date: Mar 2017 Motorcycle(s): 2007 Kawasaki 250 Ninja, 1982 Honda Ascot FT500 Posts: A lot.
|
Quote:
Bill
__________________________________________________
Insanity: doing the same thing over and over again expecting different results each time. |
|
|
May 9th, 2018, 11:17 PM | #9 |
ninjette.org certified postwhore
Name: AKA JacRyann
Location: Mesa, AZ
Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot.
MOTY - 2018, MOTM - Nov '17
|
Yeah, outermost disc is different on 2007 as well. Make sure you don't have an inner plate in outermost position.
|
|
May 10th, 2018, 06:31 AM | #10 |
ninjette.org newbie
Name: Zipporah
Location: LA
Join Date: Aug 2017 Motorcycle(s): 2007 Ninja 250 Posts: 5
|
That's what's weird and not making sense. I took the clutch plates and discs from the bike where the clutch was working fine and put them directly in this bike. Didn't change the order of them or anything. Just took out the good stack and installed them thinking that would solve the problem. I wonder if I should just exchange the whole basket from the working bike?
|
|
May 10th, 2018, 06:47 AM | #11 |
ninjette.org certified postwhore
Name: AKA JacRyann
Location: Mesa, AZ
Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot.
MOTY - 2018, MOTM - Nov '17
|
Which pressure plate did you use? Keep that matched up with same basket.
You might have bad combo on your bike and putting in different discs won’t change that. Also something may be going on with release lever and cam. Usually stroke starts before 90-degrees, moves through 90-degrees when you squeeze lever and end up same amount on other side of 90-degrees. Your lever’s already at 90-degrees in resting state, strange... |
|
May 10th, 2018, 06:58 AM | #12 |
ninjette.org certified postwhore
Name: Tom
Location: Northern Virginia
Join Date: Jul 2015 Motorcycle(s): 2001 Ninja 250, 2019 Harley Ultra Classic, 2001 Suzuki SV650 Posts: A lot.
MOTM - Jan '16
|
Did you rotate the pressure plate 90 degrees from it's original installation?
https://forums.ninja250.org/posting....&t=88789&tro=1 |
|
May 10th, 2018, 07:13 AM | #13 | ||
ninjette.org newbie
Name: Zipporah
Location: LA
Join Date: Aug 2017 Motorcycle(s): 2007 Ninja 250 Posts: 5
|
Quote:
Quote:
I've been messing with this thing so long. I just know that if I take it to the dealer that it's most likely going to be something simple and they're going to charge me some crazy amount to fix it. |
||
|
September 23rd, 2019, 09:34 PM | #14 |
ninjette.org newbie
Name: Aaron
Location: Kernersville
Join Date: Sep 2019 Motorcycle(s): Ninja 300 Posts: 2
|
A google search landed me here today. Wanted to post my solution in case it helps someone else. Made a complete DIY for the clutch replacement, including the troubleshooting and solution.
https://youtu.be/7WfanW3tGZk |
|
Similar Threads | ||||
Thread | Thread Starter | Forum | Replies | Last Post |
Clutch Won't Disengage | Gmon | 1986 - 2007 Ninja 250R Tech Talk | 21 | September 23rd, 2019 09:31 PM |
Clutch issues. Won't disengage, searched, tried, help | mr2peak | 1986 - 2007 Ninja 250R Tech Talk | 21 | May 5th, 2014 04:32 PM |
Clutch doesn't fully disengage power when pulled in. | reaubideux | 2008 - 2012 Ninja 250R Tech Talk | 11 | November 3rd, 2011 10:11 AM |
Another Clutch Issue...Cannot Disengage! | Littlefreak | 1986 - 2007 Ninja 250R Tech Talk | 8 | March 13th, 2011 09:15 PM |
Improperly disengage clutch ~ revs high, lower speed. | Ntotot | 2008 - 2012 Ninja 250R Tech Talk | 12 | August 26th, 2009 10:48 PM |
|
|