85 250r clutch help please!!!!

[rouseanator]

250R's produce a lot of noise from the counter balancer that sounds like rattling. These are older engines and the straight cut gears that drive the balancer will develop some increased backlash over the years. If the noise doesn't change with pressure on the clutch lever I would suspect the balancer is the sound you are hearing. they can be rebuilt with new bearings but the gears are discontinued.

Ross..

So I have read up some on the counter balancer and kind of understand it now, the clutch is very easy to pull and doesn't seem to do anything at all idling or revving, looks to be a common problem so will check it out and also the clutch cause I am pretty sure it isn't working. The sound seems to be constant and doesn't change in loudness or speed up with revving the motor, just kind of gets drowned out buy the exhaust noise when revving the motor.

[rouseanator]

rouse,
I would check if there is an extra spring on the kicker shaft behind the big gear. Could be the source of the chatter.

I will check that too when I pull it off.

[jakep53]

It seems to do it all the time just cant hear it over the exhaust when reving up the motor, and seems to stay the same speed even when reving so I doubt its the piston slap cause wouldn't that make the noise get faster when reving?

Both of my 82r engines have a knock but only at a very low idle so that led me to believe counterbalancer and it hasn't caused any problems so i just left it!!

[Red Rider]

I have seen the flywheel rivets work themselves loose which leads to chatter from the flywheel as well.

[82 250r]

There should be a ball at the end of the clutch rod as well...make sure it's still there.
The clutch should always have some resistance because of the springs on the basket.

[rouseanator]

https://www.facebook.com/video.php?v=1068948856466001
So removed the right crank case cover to inspect things, the counter balancer seems fine almost no movement at all, the clutch looks pretty good also removed the clutch spring bolts and springs and pressure plate and every thing looks good to me took out the clutch lifter and NO STEEL BALL to be found, could this be why there is hardly no resistance on the clutch lever. The kick start seems to have some play in it any suggestions on that.

[rouseanator]

There should be a ball at the end of the clutch rod as well...make sure it's still there.
The clutch should always have some resistance because of the springs on the basket.

Wow pretty sure you nailed that one...... thanks. The steel ball is only 46 cents, I wander if it fell out in the engine, or maybe the last owner rebuilt the clutch and forgot it.

[rouseanator]

the clutch discs and pads look pretty good, clutch basket I dont know what do you guys think??

[rouseanator]

Wow pretty sure you nailed that one...... thanks. The steel ball is only 46 cents, I wander if it fell out in the engine, or maybe the last owner rebuilt the clutch and forgot it.

Well crap, found the little steel ball..... it was inside the clutch lifter, had to hit it a few times to get it to come out. So back to square one.

[rouseanator]

Here are some pics of measuring the clutch components and specs.
clutch spring: 45 mm
clutch outer guide: 27.97 mm
clutch disc: 2.85 mm

So looks like the springs are under the limit? could this cause almost no clutch resistance?
also the outer guide just just shy of spec.

[El Camexican]

Honda calls for 7 friction plates. I count 6 in your photo. Can you confirm 7? How much free play do you have in your clutch cable? You can set it pretty close without the clutch installed if you want. Just put your finger on the push rod to determine when movement starts.

[rouseanator]

Honda calls for 7 friction plates. I count 6 in your photo. Can you confirm 7? How much free play do you have in your clutch cable? You can set it pretty close without the clutch installed if you want. Just put your finger on the push rod to determine when movement starts.

Yes counted 7 clutch discs and 6 clutch plates, the cable is a new motion pro cable, when the clutch lifter and steel ball are on the end of the rod it moves out 3.90 mm, it pretty much starts moving rite away. To make it seem like the lifter lever is pulling in far enough, the 2 bolts on the cable are all the way to the right or towards the rear of the machine that's the max adjustment. the adjustment on the handle bar side is aliitle more than half way out.

[El Camexican]

Well, then it sounds like it's time for new springs.

[rdonald1979]

And take that basket out and sand the tabs with some emery cloth.

[250rRoostmaster]

Well crap, found the little steel ball..... it was inside the clutch lifter, had to hit it a few times to get it to come out. So back to square one.

You should do the 89 clutch upgrade, no more little steel ball to lose lol