250r clutch problem. help please

[ToddFrydrych]

hey. i pulled the clutch lever in on my 250r and the cable broke. it was a little harder to pull then normal i thought too. so i was going to try to limp it home by just moving the clutch lever on the motor to shift. but that doesnt work. i will move the lever then go to shift into gear and it jumps forward and snubs out. so it seems like the clutch lever is not hooked up inside the motor??? what do you guys think is wrong

[seadoo650]

Are you using a pair of pliers to move the clutch lever at the motor? I doubt you could actuate it by hand. If that's the case, you're not moving it far enough to activate the clutch.

[ToddFrydrych]

the clutch lever on the motor moves fairly easily by hand... :confused:

[factoryX]

time for a new clutch/springs....

[ToddFrydrych]

how big of a job is it to fix this?

[ToddFrydrych]

is it possible something just came unhooked in the motor?

[seadoo650]

I doubt anything came unhooked. Maybe some broke or weak springs. Very easy fix. Drain the rads, drain the oil, pull rad hoses, remove kicker, pull cover. Download a manual from here on the site. I believe Dammit has a link for them. Check back when you get it apart and find anything out of the ordinary.

[ToddFrydrych]

i never said but this is a 81 250r. does this change anything??? i assume u were thinking 85 or 86

[seadoo650]

Actually yea, I was. Deffinately get a manual. Other first gen 250r owners are here too. I'm sure someone with more knowledge than myself will chime in. Good luck.

[ToddFrydrych]

ok ill wait for someone to help out

[kkvslayer]

Pull the round clutch cover and you'll see your basket,you can visually inspect the basket from here,best bet will be to remove the springs/bolts,the pressure plate will then come off,when you remove the lifter in the center of the hub be sure not to drop the little bb in there,it has to be there for your clutch to work properly,you can then pull the rod and pull the actuating arm on the other side where your cable hooks up,to pull the arm you need to remove the phillips screw located on the side on the case just below the arm,you can inspect your clutch plates as well,your basket could be grooved causing your lates to stick which could cause your cluth pull to be harder then normal

[ToddFrydrych]

it did pull hard but not no more. it moves easy as pie

[MonroeMike]

Manual

http://72.52.143.80/~trikes/atc250r_81-84_servicemanual.pdf