Okay,

I somewhat abused my CoolSports 250 last ride and fused my clutch plates when it overheated.

I have ht eprts, and disassembled the engine. I can't get the clutch basket out! Towards teh front of the engine is part of the oil pump{?} and it overlaps the clutch assembly. I can't get that pump aparts to remove the part overlapping the clutch. I get the cover off, but it has some type of weird nut holding the top part on. It's round, with 4 slots cut in the edge and it sits inside the "bell shaped" housing. This "nut" holds the top piece on the stalk which meshes with the gear. Anyone know how to get it off? Here's pics of it:
Engine
Engine Closeup of oil pump


I'm at a stand-still and would love to get this finished. Any help would be GREATLY appreciated!

PS - Got my nerf bars on! They are for a Honda TRX 450, but fit good with a hole drilled and some P clamps.
Nerf Bars

 

BigDaddyTX,

It is kind of hard to tell with out having the service manual. My best guess would be to remover the sliver plate holding the bearing into place. #1 on your pic. Try removing the two bolts on the lower cover to see what is behind it.#2 & #3 It may be that is what is holding the bearing plate and gear into place. Also look at #4 see what that lever is holding. You may have to remove the snap ring to remove the lever, it may release the clutch basket. But again it is hard to tell.


Good Luck.

SB.

 

I'll give it a shot. #3 is the "bell houysing" with what is apparently a nut of some sort inside. Maybe releaseing the bearing will release that whole assembly.

I'll try to remove more stuff. That bell housing is blocking the whole clutch assembly. I don't think #4 will really do anything, but I'm willing to try.

If you have further thoughts, or anyone elese does. please post them up. I'll report back once I dig into it more.

 

How about a snap ring or some sort of locking collar here? #1


Come on guys/gals any other ideas out there? [img]i/expressions/face-icon-small-smile.gif[/img]


SB.

 

BigDaddyTX,

I was curious so I went and looked in one of my CRF service manuals. There is a lock nut you need to remove inside the oil filter rotor housing. It seems I have the same setup. PM me with your email and I will send you the oil filter rotor removal and the clutch removal and servicing. Give me some time I need to scan the pages.

Do not remove bolts 2 and 3 that is the oil pump it will not help you remove the housing, leave #4 alone too.

SB.

 

BigDaddyTX,

Check your P.M. I left you a link to download the files.


SB.

 

SB.

Thanks for the info. I'll check it out. I PM'd you about specifics on the tool for removing that locking nut.

 

Here is one link so far.

More to come.

Lock Nut Tool

 

I really appreciate your taking the time to get me some info. You're definitely saving my bacon on this one.


What ATV is that manual for, it looks like my engine is almost a perfect duplicate.

 

It is not an ATV manual. The manual is for a 2003/2004CRF150 Dirt Bike.

I am glad I could help. [img]i/expressions/face-icon-small-smile.gif[/img]

Let me know if you need anything else. [img]i/expressions/face-icon-small-smile.gif[/img]

SB.