HELP!!!Baja dirt runner 125 clutch assembly

Gregalis08 · 07-10-2019, 04:33 PM

Hi everyone new to the forum and looking to get some feedback on my recently purchased Baja 125 dirt runner! Picked the bike up for cheap ran fairly decently when purchased but the clutch cable was snapped and tires both flat, replaced clutch cable and could not get the clutch to disengage while in gear so the bike could not roll with the lever on the crankcase fully engaged.... drained oil removed crankcase cover and removed clutch basket assembly and inspected. I’m not familiar with these but everything looked normal and the friction disc are not glazed and no shavings of metal in the oil. My first guess was possibly springs are bad, there isn’t a manual out for this bike that I know of just wondering if I missed something or maybe someone installed parts wrong before I got the bike.... anything helps... also I did find an electronic parts catalog and it looks like all the parts for the clutch basket assembly are there and installed in proper order

**JerryHawk250** · 07-10-2019, 04:38 PM

Welcome aboard! If the bike was set up for a while the disc may be stuck together. Try laying the bike on its side over night on the clutch side. The dried out disc will soak up some oil and this might get them unstuck. If not you will need to pull the clutch pack as separate them manually. You can get the entire clutch pack for under $20.

Gregalis08 · 07-10-2019, 04:42 PM

Thanks for the advice as I said above I have already removed the clutch basket and the disc seem fine they are not stuck

**JerryHawk250** · 07-10-2019, 04:46 PM

Quote:

Originally Posted by Gregalis08

Thanks for the advice as I said above I have already removed the clutch basket and the disc seem fine they are not stuck

Sorry, I missed that.

**JerryHawk250** · 07-10-2019, 04:56 PM

Do you think the actuator rod is worn down too much to disengage the clutch?

Gregalis08 · 07-10-2019, 05:13 PM

I’m not really sure which part that is if you are referring to the pin inside the bearing assembly it is fine I can see very little wear on it it’s painted black and has very light silver scoring so I would say it’s fine

**JerryHawk250** · 07-10-2019, 05:23 PM

Try adjusting the clutch at the engine. Here's a tutorial on how to do it. https://tboltusa.com/store/tech.php?...tch+Adjustment

Gregalis08 · 07-10-2019, 05:51 PM

That is a lot different then my clutch assembley I do not see any adjustments

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dirtbkr188 · 07-10-2019, 06:08 PM

Something doesn't look right in the bottom pic, it looks as though you don't have enough clutch plates under the outer pressure plate, it is recessed inward. Normally, that outer pressure plate sits flush with the outer edges of the clutch basket.

Gregalis08 · 07-10-2019, 06:11 PM

Ok thanks I’ll try that and get back to you!

Gregalis08 · 07-10-2019, 06:18 PM

This is a current picture they way I have it installed now with tension on springs but the clutch basket can slide with my hand if I hold the outer assembly

humanbeing · 07-10-2019, 06:38 PM

It just as 90's kick ONLY CG125. If u search 'net: Haynes (pre CDI model) & CGR125 storm (e-start model ) service manual pdf can easily found . The one (Kick ONLY, CDi) resembles ur bike's engine is in Brazilian Portuguese.

Unusual way to repair old CG http://www.chyangwa.net/forum.php?mo...authorid=75082

Gregalis08 · 07-10-2019, 07:36 PM

Ok thanks it looks like I am missing a piece that sits in front of the bearing

**JerryHawk250** · 07-10-2019, 08:01 PM

Oh I see you have a cg125 and not horizontal 125. You have the same style clutch as the cg250. I have couple of manual I can email you tomorrow. I don't have them on my home computer.

Gregalis08 · 07-10-2019, 08:22 PM

Ok thanks appreciate all the help, this forum is great!

07-10-2019, 04:33 PM	#1
Gregalis08 Join Date: Jul 2019 Posts: 12	HELP!!!Baja dirt runner 125 clutch assembly Hi everyone new to the forum and looking to get some feedback on my recently purchased Baja 125 dirt runner! Picked the bike up for cheap ran fairly decently when purchased but the clutch cable was snapped and tires both flat, replaced clutch cable and could not get the clutch to disengage while in gear so the bike could not roll with the lever on the crankcase fully engaged.... drained oil removed crankcase cover and removed clutch basket assembly and inspected. I’m not familiar with these but everything looked normal and the friction disc are not glazed and no shavings of metal in the oil. My first guess was possibly springs are bad, there isn’t a manual out for this bike that I know of just wondering if I missed something or maybe someone installed parts wrong before I got the bike.... anything helps... also I did find an electronic parts catalog and it looks like all the parts for the clutch basket assembly are there and installed in proper order
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07-10-2019, 04:38 PM	#2
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,551	Welcome aboard! If the bike was set up for a while the disc may be stuck together. Try laying the bike on its side over night on the clutch side. The dried out disc will soak up some oil and this might get them unstuck. If not you will need to pull the clutch pack as separate them manually. You can get the entire clutch pack for under $20. __________________ 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
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07-10-2019, 04:56 PM	#5
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,551	Do you think the actuator rod is worn down too much to disengage the clutch? __________________ 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
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07-10-2019, 05:23 PM	#7
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,551	Try adjusting the clutch at the engine. Here's a tutorial on how to do it. https://tboltusa.com/store/tech.php?...tch+Adjustment __________________ 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
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07-10-2019, 06:38 PM	#12
humanbeing Join Date: Mar 2008 Posts: 2,436	It just as 90's kick ONLY CG125. If u search 'net: Haynes (pre CDI model) & CGR125 storm (e-start model ) service manual pdf can easily found . The one (Kick ONLY, CDi) resembles ur bike's engine is in Brazilian Portuguese. Unusual way to repair old CG http://www.chyangwa.net/forum.php?mo...authorid=75082 __________________ Last edited by humanbeing; 07-10-2019 at 07:58 PM.
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07-10-2019, 04:42 PM	#3
Gregalis08 Join Date: Jul 2019 Posts: 12	Thanks for the advice as I said above I have already removed the clutch basket and the disc seem fine they are not stuck
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07-10-2019, 05:13 PM	#6
Gregalis08 Join Date: Jul 2019 Posts: 12	I’m not really sure which part that is if you are referring to the pin inside the bearing assembly it is fine I can see very little wear on it it’s painted black and has very light silver scoring so I would say it’s fine
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07-10-2019, 06:08 PM	#9
dirtbkr188 Join Date: Aug 2009 Posts: 496	Something doesn't look right in the bottom pic, it looks as though you don't have enough clutch plates under the outer pressure plate, it is recessed inward. Normally, that outer pressure plate sits flush with the outer edges of the clutch basket.
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07-10-2019, 06:11 PM	#10
Gregalis08 Join Date: Jul 2019 Posts: 12	Ok thanks I’ll try that and get back to you!
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07-10-2019, 06:18 PM	#11
Gregalis08 Join Date: Jul 2019 Posts: 12	This is a current picture they way I have it installed now with tension on springs but the clutch basket can slide with my hand if I hold the outer assembly
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07-10-2019, 08:01 PM	#14
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,551	Oh I see you have a cg125 and not horizontal 125. You have the same style clutch as the cg250. I have couple of manual I can email you tomorrow. I don't have them on my home computer. __________________ 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
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07-10-2019, 08:22 PM	#15
Gregalis08 Join Date: Jul 2019 Posts: 12	Ok thanks appreciate all the help, this forum is great!
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