Another SR250 - The Police

That all looks ok. Are all the washers inside placed right? Very weird it would stop all of a sudden unless something broke or came loose. Did you check all the washers etc. for cracks? The broken spring to me indicates something started to bind and the spring could no longer return the arm and being old metal te fatigue broke it. Somewhere there has to be a moving part worn or damaged to cause this issue.
 
I looked at a larger fiche and I would inspect the parts for the push rod, like the ball bearing (#30) is installed correctly and that the bearing on the pivot are not worn out #27 #28 and the other parts around the push and pivot.
 
all the washers in place, all the sprrings intact. i didnt do anything around engine. only frame, tank, frontend mods.
 
looking into all that parts I would need to open entire engine!? and i don't have clutch removal tool :S
 
Bummer, your clutch is on the oposite side of the bike from the actuator etc isn't it. Makes it harder to find the issue. Maybe someone with more SR knowledge will chime it and have an idea.
 
btw i oiled the cable, i still think cable is not an issue but to be on the safe side im ordering new one as i type
 
how bad cable must be that springs in assembly cant return it?? really bad? this one is not that bad, still feels smooth
 
Hi all,

need an suggestion how to secure the tank. I have removed that extension on the end of the tank where it is bolted to the frame:
9179FBD5-EB6A-4ECB-B685-8677FBCCADD1.JPG

And now I'm looking for alternative way to secure it to the frame.
Maybe welding a bracket somewhere with a hole for bolt, will that be ok?
 
the cable is not the issue with your clutch. did you install the spring on top of the engine case correctly? if you were driving the bike two weeks ago with no problems it is not a major issue, as it wouldn't get damaged overnight.

the clutch plates tend to bind if the bike has been standing for a while making it impossible to move the bike.
 
jup, spring is installed correctly. plates are not stuck together i took them out and cleaned.
i tried to attach cable to the rod and pull it with hands...it returns normaly. when i try it with lever like it should...it doesnt return. i'm waiting for new cable...we will see.
 
Was wondering if you touched or tightened the pivot bolt for the hand lever? I over tightened mine and it was acting same way. I loosened it and it works much better now.
 
interceptor said:
Was wondering if you touched or tightened the pivot bolt for the hand lever? I over tightened mine and it was acting same way. I loosened it and it works much better now.
Click to expand...

I did this once too. Check it and see.
 
the cable was not the issue, it was the nut...

anyway got new trouble, im in process of rewireing and i have disconected starter relay and now i dont know wich side goes to battery and wich side goes down in crankcase...help :(
 
Do these help:
 

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I cant tell, it doesnt look the same.
Mine is hitachi ms5d-191
http://img.auctiva.com/imgdata/1/4/5/4/6/0/8/webimg/533386237_o.jpg
 
Af far ias i know i doesn't matter. The relais (actuator) connects the 2 big contactpoints (m6) when power is applied to the small wires. It doesn't matter wich wire goes where on this particular part. If you're still in doubt you could open it to see what happens when power is applied.

Don't take my words for wisdom, i could be wrong.
 
So yeah I finally finished this :D
This is what it looks like now;
3E67CB49-07B5-46CE-A9C5-6212EEF1B55D.JPG

I'm really unhappy with front end...its fugly as hell :-/ but I had no more resources (cash or time) to make it look nicer. And I just wanted to ride it.
 
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