Author Topic: Clutch Problem - Not Engaging (Read 2959 times)

Sean86250R · « **on:** February 01, 2015, 12:20:35 AM »

Hello,

I need some help. I recently took the clutch out of my 250R because it wouldn't find neutral except when not running. So, I believed the basket may need filed and it did. So, I filed the basket ears and seemingly did it right. It seems to have an 89 upgrade clutch with the flat needle bearing on the push rod.

When I had it apart, I do not think there was a washer/spacer between the flat needle bearing and the pressure plate, so I (excuse my ignorance on this one) used a cut washer that seemed the right size and put one in...

The reassembly went fine, I may have overtightened the clutch springs from what I can tell, but there were no issues.

When I fired it up.... it will shift, BUT the clutch will only grab enough so the quad just barely moves...like barely moves at all. So, for whatever reason, I made things worse....

Two questions, did I screw up by really tightenting the clutch springs a lot and I am guessing I better get the actual washer/spacer that goes between the flat needle bearing and the pressure plate.

Any thoughts would be great.

Thanks
Sean

2ndmoto · « **Reply #1 on:** February 01, 2015, 01:52:29 AM »

Unless you stripped the bolt holes, over tightening is not causing your issue. My guess is the washer is too thick. If I recall correctly it is about1mm thick.

Is your cable adjusted right? You should have ~.125" - .25" of free play at the lever.

Best regards
-Jason

Sean86250R · « **Reply #2 on:** February 01, 2015, 02:05:22 AM »

Thanks Jason. Cable ought to be good. Brand new and was working fine before I took it apart. The washer I put in couldn't have been much more than a mm, but maybe. I'm going to take it back apart and check everything out.

I swear there wasn't even a washer in there when I took it apart, but the needle bearing would eat into the pressure plate wouldn't it?

broken1 · « **Reply #3 on:** February 01, 2015, 02:41:51 AM »

Make sure theres a little play at the actuator arm. The 89 upgrade includes a pressure plate, are you sure you have the 89 plate because it has a deeper pocket machined for the bearing. I had a problem with mine not engaging when I did the clutch upgrade with used parts & ended up having to grind down the push rod a little at a time to get the clutch to engage all the way. I'm not saying the way I did it is right but it worked.

fearlessfred · « **Reply #4 on:** February 01, 2015, 12:50:33 PM »

washer has to be to thick and you could put all the freeplay in cable that you wanted and it would make no diff,I think I have that washer on the bench if you needed measurement