Help! clutch differences between 85/86 250r?

[SteveCZ28]

ok, i figured id make a thread strictly on the clutch on my 250r. i have a 85 r, with a 86 trx 250r motor in it....im having issues with my clutch. my cable just simply wont pull the clutch out enough to disengage it. i tried a brand new cable, but still same issue. there is about a 1/4 turns worth of free play in the clutch actuator rod. i took both clutches apart on both my 85 motor and this new 86 motor, and found the actual clutch rod (the rod that pushes into the pressure plate) was about 1/4 inch shorter in the 86 motor...so i swapped my longer rod into the 86 motor and still have the same issues....i was talkign to a guy at work about this and he said check the bracket that holds the cable itself to the motor....

at last, i found a possible culprit. i did find that both the 85 and 86 trx 250r and 86 atc 250r's had different clutch cable holders on the motor. both the 86 atc/trx have the same bracket....but are these 2 brackets really that different???

what im hoping for is for someone to maybe help me with a picture of this bracket, or maybe some different ideas on what my clutch issue could be.....any help, input or ideas would be very helpful at this point

[falloutboy]

is the ball bearing still in there, on the end of the rod. #28

[SteveCZ28]

yes it is in both rod ends on each motor.....and their both free and not stuck

[Dirtcrasher]

Your rod is too short, check the spec. Should only be 1 ball......

Best thing for these is the 89 update kit.

[SteveCZ28]

sorry to confuse you. there is one ball on one end of the rod, on both motors. 1 ball and rod per motor... but how would the rod be too short tho? where do i find the spec size for this rod?

[Dirtcrasher]

The rod and pivot arm wear out, I imagine the shop service manual has the spec.

Again, just buy the 89 update kit for 85$ and you'll be much happier......

[SteveCZ28]

can you tell me if part number 10 in this pic is adjustable???? or whjat is the difference between the 85/86 to this 89??

[SteveCZ28]

if i buy the 89 kit does it come with a new pivot arm??

[Dirtcrasher]

No, not adjustable. No, no pivot arm. If your arm is worn, thats part of your issue........

You get a new rod that works with a thrust bearing (and washers) for smoother action.

Do a search, I even tossed them in the 85R I had when I had cable issues and action that wasn't smooth.

[SteveCZ28]

well i just found the 89 kit on ebay for 65 bucks shipped, so i bought it. cant go wrong. ill inspect the pivot arms when i get home from work, and might buy as new one of those as well

[SteveCZ28]

did some tinkering today. took both pivot arms out of both of my motors...the pivot arm in the 86 motor had a good sized dent/divet where the pusher rod rests on it. where as my 85 pivot arm looked fine. so i put my 85 arm into the 86 motor, and now i have very minimal free play in the arm before it tries to disengage the pressure plate. it does disengage it a good amount but it still does drag a tiny bit. so all i can really hope for now is the new 89 kit will solve the rest of this issue, or ill be forced to make a longer push rod

[ceaserthethird]

$65 for the update kit, Can you post a link ?

[Blown 331]

I had the same problem on my 85 250R when switching to a newer engine. I drilled a second hole in the cable mounting bracket that bolts to the engine and moved the bracket farther forward. Problem solved.

[SteveCZ28]

$65 for the update kit, Can you post a link ?

i just got lucky. i started using the part numbers for the update kit from different parts sites, and started searching those numbers on ebay, and found just a normal guy (as in not a ebay business/store) that had one for sale so i snatched it up. still brand new in packaging

[SteveCZ28]

I had the same problem on my 85 250R when switching to a newer engine. I drilled a second hole in the cable mounting bracket that bolts to the engine and moved the bracket farther forward. Problem solved.

i was considering modifying that bracket also