Restoring a 84 250r ATC

[That250r]

This has been a battle! I finally got her running today but when I pull the clutch in its like it doesn't engage at all? When you put it in gear it just try's to go and shuts off? Is there a secret to these clutches or do I just have to get a new one and if that's the case is this a DIY project or should I take it to the shop? I am handy enough in most cases.

[RIDE-RED 250r]

If I understand your meaning, it sounds to me like your clutch basket fingers are likely galled up.


A worse case but less likely is something mechanically broken in your clutch actuator/linkage.

But before you dog into diagnosing a problem with the clutch or the other components that control it, make sure your clutch cable is properly adjusted. You should be able to pull the clutch lever in slightly before feeling resistance. This is known as "free play". Rule of thumb for most manual clutch equipped machines is you should have about 1/8" free play. Where you measure is between the clutch lever and the clutch perch right where the cable comes out of the lever. Just pull the clutch lever in right till you begin you feel the resistance of the clutch pulling back, then check the gap between the lever and perch....

If that checks out...
Pull the clutch cover, then remove the clutch pressure plate and remove all of the clutch plates and discs you will be able to easily inspect the clutch basket fingers. If they look all bumpy/wavy on the fingers where the tabs of the friction discs push against them that will be your problem. If they aren't real bad you can smooth them up with a flat file. Just don't go crazy with it.

[That250r]

Thank you for the response! I actually am manually trying to engage the clutch because the cable is shot also lol. I will pull the cover off and inspect everything tonight! Thank you once again and I will let you know what happens!

[RIDE-RED 250r]

Well, first things first. Replace the clutch cable! That could be all your trouble is....