250sx clutch over HELP!! PLEASEEEEE!!!!!!!!

[Bigred200]

Ok really simple I though.. I took my clutch cover off to get it polished it came right off without a problem, now it wont go back on what am I doing wrong ive look all the way around it but it only goes on maybe a eighth of the way please what am i doing wrong Im getting aggrevated bad...any help???????????????.

[whittim]

I'm assume you mean the right side cover, they can be a little tricky to get all the dowels and shafts lined up when putting back together.. remember to double check that everything is aligned then with alot of wiggling and tapping with a sand hammer or a rubber one it shoud pop back

[tri again]

My last trip into a side cover was a 125 but I remember tons of levers and rods that are held in place by gravity and sheer luck.

It doesn't take much for a few things to rotate out of place.
My saving grace was to take apart a junker and freak out and then the real one got tipped flat with the side cover straight up and I touched NOthing except the cover and the gasket change and it was still a wiggle match to get it back on.

I'd look for a picture of one with the side cover off.
The search key is working great these days.

I might have an sx with all the side cover bolts off but not sure if all the parts are
still in there.

Did you say the cover only goes on an 8th of the way. like a few inches out?
or more like an 8th inch from being seated.

[Bigred200]

few inches out barely on

[Yamaha_Rules69]

Is it hanging up on the clutch adjustment bolt/rod? This seems like such a simple task, maybe get a flashlight, and try to look inside as the cover is on, and see whats catching? You could also use a long screwdriver or similar to try to feel what is hanging up. It cant be too hard, I think your over looking it! Hope you get it figured out.

[Dirtcrasher]

Reverse lock? The arm that engages the main clutch? Did anything come off (fall off) when you removed it? Sounds like something very simple but easily overlooked......

[James S]

yeah , i just pulled my side cover off 4 times. I had a kickstarter issue, and i have had to keep trying to fix it. As long as you make sure that reverse lifter in sitting in the motor first and not
sitting in the cover you should be fine. This lever is the only thing that could be holding you up. Everything else should be no problem,

[Howdy]

I'm with Dirtcrasher and James. That reverse lever can be a P.I.T.A. sometimes.
Howdy