Clutch lever has too much clearance to disengage clutch after clutch rebuild - Honda Rebel Forum
 
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post #1 of 4 Old 01-15-2020, 10:35 AM Thread Starter
 
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Question Clutch lever has too much clearance to disengage clutch after clutch rebuild

After rebuilding the clutch on my 1986 rebel 250, the clutch lever on the right-side crankcase cover has too much clearance while being pulled to disengage the clutch. I've tightened the clutch cable all the way, and the lever bottoms out before the clutch is disengaged. Its like you have to pull the crankcase lever a good inch in before you even feel any resistance from the springs.

I did notice the friction plates I purchased said it was for 1987-2014 rebels, but I'm not sure that is the problem. Does anyone know if 1987 friction plates are compatible with 1986 friction plates?
I'm not sure if I assembled something wrong or if the clutch plates are the problem. I've rebuilt it twice trying to figure out the problem.
Any information would be appreciated. Thank you!

Matthew Mills
1986 Rebel 250
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post #2 of 4 Old 01-15-2020, 11:38 AM
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The friction disc part numbers are the same for both 1986 and '87. However, the clutch plate numbers aren't identical. That doesn't mean the actual clutch plates for these model years aren't the same, as Honda seems to change part numbers without rhyme or reason.

Is the clutch cable adjuster on the hand lever all the way in (maximum length on cable) before adjusting the cable at the clutch end?

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
Putting your bike year and model in your signature helps others help you!
Here's how: https://www.hondarebelforum.com/f19/...re-121087.html
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post #3 of 4 Old 01-15-2020, 11:46 AM Thread Starter
 
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So, i have tried all combinations of adjusting the clutch cable. Nothing works. I think the actual lever at the crankcase cover is too loose, because it is actually almost bottoming out onto the lower clutch cable mount.

As for the plates, the plates i ordered were wrong so I actually had to use my old plates. I dont think the plates are the problem. Something is causing the clutch to be positioned too far away from where the rod and clutch lifter connect. Theres too much clearance. It might be the thickness of the friction plates? But i dont think so. I think something is assembled wrong. Ill upload pictures later today.

Matthew Mills
1986 Rebel 250
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post #4 of 4 Old 01-15-2020, 12:26 PM
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See if this helps. https://www.hondarebelforum.com/f76/...ge-120053.html

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
Putting your bike year and model in your signature helps others help you!
Here's how: https://www.hondarebelforum.com/f19/...re-121087.html
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