01 ec125 clutch problem

[michalt95]

so i got a 2001 ec 125 with a cr125 clutch and i have a problem

the clutch has been dragging before to the point where it would kill the engine if it was on idle and i put it into gear without revving it a little. I though no big deal..

so on last ride the clutch just quit working, i was not on the bike at the time so i can not say what exactly happened, however the lever just felt loose, it had no resistance. when i started the bike, put it into first, it stalled.

so got home, tried bleeding the system with DOT 4 (it says to use the on the cover) and it did nothing.

I did some research but still can not come with a solution

so are there any rebuild kits for this bike?
you guys got any other possible solutions??

 

[noobi]

so i got a 2001 ec 125 with a cr125 clutch and i have a problem

the clutch has been dragging before to the point where it would kill the engine if it was on idle and i put it into gear without revving it a little. I though no big deal..

so on last ride the clutch just quit working, i was not on the bike at the time so i can not say what exactly happened, however the lever just felt loose, it had no resistance. when i started the bike, put it into first, it stalled.

so got home, tried bleeding the system with DOT 4 (it says to use the on the cover) and it did nothing.

I did some research but still can not come with a solution

so are there any rebuild kits for this bike?
you guys got any other possible solutions??

The first symptom is pretty normal, I could never start my 125 in gear and it didn't like to be left at idle in gear either.

Was someone else riding the bike when it happened? If they crashed, they may have damaged the clutch.
Is there any visible leakage from the clutch system? Mainly around the master and slave cylinders. You may have had one of the seals go on the system and its no longer holding any pressure which makes the lever go limp and the clutch not work.

 

[bowhunter007]

Depending on who owned the bike before you, i.e. How many hours, abuse, lack of maintenance? It may simply need to come apart, and be replaced.

 

[GMP]

Funny, my brother/nephew owned that bike and I built it. It has a Hinson clutch that was in great shape. Its likely just an AJP master that went belly up.

 

[michalt95]

I noticed that the master was a little wet around the seal that day.
My brother took the system apart and cleaned it then trie bledding it again. Same.
He said that its probably the slave cylinder went bad.
Is there any way to figure out for sure which one went bad?
I looked at the ajp site however i did not see that you can order from there. What are other places to get the cylinder or a rebuild kit?

 

[GMP]

Unlikely. If the slave went bad it would dump brake fluid into the transmission through the leaking slave piston oring. This would foul the trans oil and make it milky just like if there was water in it. How did he attempt to bleed the system? You have to back bleed it through the slave fitting with the lever backed off enough for the holes in the master to be cleared by the piston.

 

[michalt95]

We tried a normal bleed. I will try a reverse bleed over the weekend. What would you recommend to push the fluid?

 

[GMP]

The system must be back bled, you will never be able to bleed it through the master. You need a syringe with a short piece of tubing.

 

[michalt95]

i was thinking that but wouldnt a syringe be too small tho?

 

[michalt95]

I tried reverse bleeding. Didnt work.
Is there a way to figure out which cylinder is down?

 

[roostafish]

I have had to bleed the clutch master cylinder. It is not easy, and one would think that you could just bang it out like a brake. For whatever reason, it is very difficult to bleed. From the slave cyl, force the fluid up. The only way I got it to work was to remove the clutch from the bars, hang it from the garage ceiling with the plunger backed ALL THE WAY OUT and force fluid up the line until fresh looking fluid came out. All the while, spilling all over the floor. Unhook the master from the ceiling, replace on bars and repeat very slowly until the master cylinder is filled, from the bottom. put it back together and feel the clutch again. Keep in mind, no air can get into the system, or it will not work.

 

[GMP]

It should not be the hard, the key is having the lever (master cyl) in a position that allows flow back up through the line and into the reservoir.

 

[michalt95]

havent had time to work on the bike in a long time its been just sitting there

so i found some time and tried bleeding the clutch again, i managed to get the fluid from the slave cylinder to the master, repeated that untill there was no more visible bubbled coming up in the master.

allright i think that should do it i think to my self
go to grab the lever and ...... nothing lever still feels light like there is no power

 

[michalt95]

anyone????

 

[GMP]

You either did not get all the air out as you thought, the cup seal in the master is leaking(more likely), or the oring in the slave(less likely).

 

[michalt95]

woken from the dead
havent had time at all to work on it between school work and other stuff

about how much fluid should fit in the clutch system if it was completely out??

 

[michalt95]

how much fluid in total should the clutch system take if completely out of fluid?

 

[GMP]

Never thought about that as its not important anyway. I'd guess less than 100cc. If your still fighting with that clutch you have a problem.


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[michalt95]

Bring a thread from the dead haha
Still got the bike and still got the same problem haha
The bike has been sitting the whole time and im looking to get it running again.
So my brother and I put on a new slave cylinder and still couldnt get it to work. He says that its probably a rod going from one side of the engine to the other that is too short He knows his motorcycle stuff so i believe him.

Any input on this? anywhere i could buy that "rod"?

 

[sweeper]

Bring a thread from the dead haha
Still got the bike and still got the same problem haha
The bike has been sitting the whole time and im looking to get it running again.
So my brother and I put on a new slave cylinder and still couldnt get it to work. He says that its probably a rod going from one side of the engine to the other that is too short He knows his motorcycle stuff so i believe him.

Any input on this? anywhere i could buy that "rod"?

Shouldn't need a different rod.I'm not sure how this particular clutch mod was setup.The guy that built it might have more details on that.
If I was wagering on this one Id say a ball bearing is the cure.
Push the rod in until you feel it stop.Shouldn't be much play between where the slave actuates the rod.In many cases you basicly bolt the slave to the case and compress the slave while doing so.In other words its tight and set against it.
Disconnect the master from the line and dump the fluid out.Do not actuate the lever.Hold
it upside down and shoot it with some ID Red.Just clean it up real good and get the silty crap outta the master rez.Hook the line back on.Disconnect that from the slave.Stick the end of the line in a quart container of brake fluid and fill the master rez up.Play with the levels between the two as you slowly work the lever.Just flushin crap out and makin a huge mess.If you do it right you can work a lot of the air out.You'll get the idea once you start playing with it.Once you get it as good as you can, take your line out of the quart of fluid holding it level with the level in the master rez.And thread the line and slave together.Bolt the slave back up.
A vaccuum brake bleeder and you are set.
Lots of tricks you can do to bypass the vaccuum bleeder.
But give yourself a break.