When the clutch lever is between 95 and 99% out, the bike will jerk. Once the clutch is 100% out, everything is fine and the bike runs like a top. just feels like you let the clutch out too fast right at the end of the throw.
It kind of feels like, as you let the last 5% of the clutch out, that the clutch pack finally takes hold with a thud/jerk/clunk and the bike continues on its way.
If your problem is same as described then change the Clutch housing. Don't buy honda atlas, all of them have defect. In Karachi go to Fazal Traders Aurangzeb Mkt and ask for Taiwan made housing with japan clutch plates and pressure plates.
Item no 2 and 5 is clutch housing set
Taiwan Housing Rs.600=, Clutch plate and pressure plates 1000=
I have tried original atlas honda, original F.C.C and crlf. Commonly people say that its the run-out of the housing and can be turned by machinist, i tried that too but did not worked.
The difference that i found between Taiwan housing and others was the thickness teeth/splines of part #2 in the picture.
When measured with vernier caliper Taiwan housing splines are 5.25 mm whereas others are 5.75 mm. When metals expand after engine coming to normal operating temperature the pressure plates (part#4) movement/sliding becomes rough over thicker splines and produces juddering at final grab while releasing clutch.
Moreover this juddering spoils the driving pleasure as i had started to hate my cg125 for this but after repairs I repented that i should have done this before.
