TRX250R.ORG
Workshop => Engine and Bottom End => Topic started by: Red89 on March 03, 2018, 07:19:22 PM
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Need some help guys. While riding it’s really tough to shift to 2nd gear. The shifter didn’t want to move up. When stopped it will shift no problem. I have the clutch cable adjusted all the way I can. Any idea what the problem could be? I’m hoping it’s a clutch cable problem or maybe worn clutch plates. Don’t really want to split cases.
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it shifts fine 2-3, 3-4....? when was the last time the clutch was serviced? last time the bottom end was torn apart? maybe excessive in/out play with the shift shaft?
Joe
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Another issue I've had is having the shifter positioned to high. So couldn't up shift for crap.
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Couldn’t tell you the last time it was torn apart. I’m thinking it’s a clutch issue being the issue I have and when down shifting with the clutch pulled in it kind of clunks. In other words feels like the clutch isn’t completely disengaging. Which leads me to think it’s a clutch problem. How could I tell if the clutch discs are worn?
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Couldn’t tell you the last time it was torn apart. I’m thinking it’s a clutch issue being the issue I have and when down shifting with the clutch pulled in it kind of clunks. In other words feels like the clutch isn’t completely disengaging. Which leads me to think it’s a clutch problem. How could I tell if the clutch discs are worn?
look up the service manual online or get a hard copy (my suggestion). measure the clutch free spring length, measure clutch disc thickness (fibers and plates). check for clutch disc warpage. check the clutch center and clutch outer (hub and basket) for excessive wear/grooving. check the starter idler gear and clutch outer guide. all the service limits are in the service manual.
Also, a good set of 0-1" mic's and 0-6" calipers are worth every penny. a small surface plate is useful also. clean the engine before tearing into it. don't forget to order a new clutch cover gasket when ordering parts.
Joe
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Damit joe! You beat me to it! The manual says replace at 2.85mm or .112"
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Could be a number of issues including, but not limited to:
Worn clutch basket, worn clutch plates, bent/worn shift shaft, bent/worn shift forks, worn/broken shift drum
Start with pulling off the clutch cover and inspect everything you can from there. If you can't find the culprit then it's time to split the cases and investigate further
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Could be a number of issues including, but not limited to:
Worn clutch basket, worn clutch plates, bent/worn shift shaft, bent/worn shift forks, worn/broken shift drum
Start with pulling off the clutch cover and inspect everything you can from there. If you can't find the culprit then it's time to split the cases and investigate further
That’s what I’ll do. Hoping it’s a clutch issue and not the forks, shafts or gears.
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does the shifter "bounce" when moving it to 2nd gear? any grinding sounds? when it eventually changes gear, does it "jump" forward or anything like that?
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does the shifter "bounce" when moving it to 2nd gear? any grinding sounds? when it eventually changes gear, does it "jump" forward or anything like that?
No it doesn’t do any of those things. I can pull the clutch in and push the quad forward and lift the shifter to go to second and it won’t fall into second until the quad comes to a stop then it will raise the rest of the way up and go into second. What also makes me believe that it is a clutch issue is that when in gear and clutch pulled in The quad doesn’t roll freely as if the clutch isn’t completely disengage. It will still move just not freely as if you were in neutral. Am I correct by saying it should move as if it were in neutral when in gear and clutch pulled in?
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it definitely should roll as if it were in neutral with the clutch pulled in. surely sounds like a clutch issue to me if you have none of the symptoms i mentioned.
john
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Was it working fine the last time you rode it & now all of a sudden it's not? When I push my R's around with the clutch pulled in & the transmission in first gear they both drag a little so what your experiencing by pushing yours with the clutch in is normal... If you push & pull on the shift shaft does it move in & out about 3/8"? If so than the internal c-clip got knocked out of it's shallow groove & the shaft might have become disengaged from the collar on the drum shifter. That happened to my wife's R once & it started shifting funny.
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Found the culprit. Clutch basket is grooved like none other, clutch plates were at 2.4mm, and springs need replaced as well.
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I'm assuming it's a stock basket? Probably too far gone to file down. Best to replace it with a Wiseco or Hinson basket.
Also, while it's apart you might as well perform Neil's clutch mod...
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It looks stock and is too far gone. I am replacing it with a Wiseco 👍🏻