My 250R clutch needs help!!!

[a-camp]

My clutch was making some noise when I let it out . Also had no slip, it is on or off. I pulled the basket and filed everything. Put on a new cable and lever. It pulled OK for awhile now it seems stiff again ( 2 trips ).A new OEM basket is $600 in parts. Could I have a bent rod,or arm shaft. I need a easy pull and some slip for the dunes. Springs to hard??? Whats up?

[Mr. Sandman]

You could have some bent parts, but clutch baskets can only be filed so much. It sounds like yours is worn out. Pick up new Hinson billet clutch basket, $200 +/-, measure the thickness of your old plates and drop in some new clutch plates (stock ones work best) if yours are worn out, and install an 85 clutch update kit while your in there and you should be good to go. No guarentees for an over the internet diagnosis though. :)

[a-camp]

My bike is a 86. Does Hinson make a basket that replaces OEM or do I have to change something ? What obout inner basket and presure plate?Dont I need to do all at once?

[Mr. Sandman]

You won't need the update kit then, but the 85 & 86 baskets are the same and it bolts right on with minimum mods, it's easy stuff though. The main thing you need to do is grind/bevel the edge of the primary clutch drive gear. They also make an outer hub and pressure plate, but unless your clutch it totally toasted, you shouldn't need to replace those items. They are also very pricey. I replaced my basket and clutch plates just last year and I've had the bike for 20 years now. Go to http://www.hinsonracing.com to check things out.

[a-camp]

Is the gear on the back of the basket? Does not look like it.

[a-camp]

If the sides of the basket are not groved how does it make it hard to pull ?

[Mr. Sandman]

The instructions are very detailed but the gear is about 2 1/2" in diameter and it is pressed into the basket from the back side. I can't remember the exact process but you bevel the gear and then put it in the freezer for a while. At the same time, you heat the basket in the oven and when your ready, the gear drops right in.

[Mr. Sandman]

If the sides of the basket are not groved how does it make it hard to pull ?
The grooves in the edges of the basket fingers are not supposed to be there. They are wear marks from the clutch plates and when they get deep enough the plates stick and don't retract smoothly. Filing the edges eliminates the grooves, but the basket can only be filed so much before it needs to be replaced.