need 250sx clutch help

[86trizinger]

My engine is up and running with the rebuilt engine finally with some help from my brother while I was in class.

Something is up with the clutch though. I tried adjusting it but I don't get any tension on the screw at all. It does make it engage hard or soft still though. When I go to ride lightly in the low gears it accelerates fine. If I go more then full throttle it will lift the front wheel an inch and then feel like it hits the rev limiter. No matter matter what I do it does not pull the front wheel off of the ground. Once I get up into the other gears I can feel any slipping under full throttle.

I know it has a centrifugal clutch and manual clutch. I am not sure which is causing my problem.
Any input you have would be great.

[86trizinger]

anyone at all?

[Thorpe]

Same old clutch that was in it before the rebuild? Sounds like my BR clutch till I rebuilt it a month or two back... Put a fresh clutch and heavier springs in and it really was noticable how bad my 25 y/o clutch was...

[86trizinger]

The previous owner said they put a clutch in it, when I pulled it apart it looked new so I just put it back together.

Did you do the plates and disks both ? What brand?

[Dirtcrasher]

Bouncing off a rev limiter and a clutch not working are 2 different things.......

If the main manual clutch is slipping, and the adjusting nut/stud never contacts it, your missing the end piece in the clutch that the mechanical pivot rod contacts, a thrust washer is missing, possibly behind the basket, or the clutch is smoked.

Make sure the "clyuch lifter piece" is contacting the mechanical arm that touches it and your adjustment affects.

The steel plates should have no blueing or warpage and the fibers should be up to spec.

Take it apart and with a diagram next to it, make sure all the pieces are in place, and the reverse lock mechanism.

Back the adjuster all the way off and set it once your all buttoned up.....

Let us know :D

[86trizinger]

Not sure when I am going to get to it.. But my brother is free tomorrow night so maybe he will pull it apart for me. I am not home from class until almost 11 pm tomorrow.

The adjustment does affect the clutch engagement you just never get any tension on it and it sticks when I try to adjust it. I know the end piece is in the clutch I made sure of that before i put it back together.

[Thorpe]

When it comes to the working of a SX/ES motor, DC is the king... I will step down, and encourage to follow his advice...

[Dirtcrasher]

^ THanks Thorpe :beer

Does the adjusting stud "stick" because a large screwdriver got used in it sometime ago and the threads are bugged up? are you backing the lock nut all the way off??

Any of the 2 thrust washers in the clutch assembly missing would make it tough to adjust.

Your still scaring me with the "bouncing off the rev limiter comment"; I think you guys all need helmet cams with sound to help figure out whats wrong :lol:

[86trizinger]

What I mean about bouncing off the rev limiter is this.. When I am coasting in 1st or 2nd gear I push full throttle,, clutch grabs for a second and then engine continues to rev but barely any acceleration. In 3rd gear and up it seems to grab fine through the gears.

The threads were fine from what I could see before but I will double check that and I took the nut off of it. As for the 2 shims in the clutch I only remember on washer in the clutch, i just saw the diagram so I need to double check that. Since the previous owner did do the clutch he may have forgotten the shim.

[86trizinger]

finally got a chance to take it apart at 2 am yesterday. I found it was missing the inner thrust washer. I also found a hairline crack in the pressure plate. The clutch disc's were at 2.62 mm .. the service limit is 2.3mm . Should I go ahead and put new a new clutch in it while it is apart.

I found a NOS centrifugal clutch for it very cheap. I went ahead and ordered that for $23 shipped. I am just trying to get this running before winter.

[Thorpe]

I probably would replace them at this point, since its apart. Thinking you may have glazed them when it was slipping without that thrust washer...