85 250r clutch help please!!!!

[rouseanator]

Well, then it sounds like it's time for new springs.

Yup ordered new OEM springs from and new clutch outer guide from Rocky Mountain ATV last night should be here by Saturday I hope.

[rouseanator]

And take that basket out and sand the tabs with some emery cloth.

Well I bought some files to file them down flat already they really are not to bad.

[rouseanator]

You should do the 89 clutch upgrade, no more little steel ball to lose lol

Kind of pissed me of when I found it, cause I thought that was the problem, got a spare steel ball now. I am building it stock for now so I can feel what everything is like stock, then in the future will do some mods.

[Mosh]

If you are concerned with the knocking noise it could be a few things.
First off no chain on it is going to let the trans gear back clash against each other.
2nd off many 250R engines the clutch basket gets loose on the center collar or at the ring gear. Evidence of that will be a shiney ring on the kicker big idle gear. It is a indication that the basket is rattling against the gear. Installing a extra spring on the kicker gears is nothing I have ever heard of however some installed a extra washer to take up slack in the 85 spacers that usually resulted in slipping kickers which was later updated to one solid collar.

If you go with any aftermarket clutch basket, on the 85-86 engine the primary gear needs machined on the crank or you are going to have rubbing and grinding on the basket as it is thicker than stock was. You can search my posts and I have explained and documented this a few times on various engines.

Also the carrier bearings make no difference on any water cooled R quad or trike. They all took the same bearings UNLESS you have a aftermarket dual row carrier.
If you are talking abouth replacing the carrier as a whole with new bearings then yes..86 and up fit them all. 85 only fit the 85 swingarm.

Lastly as far as your wierd clutch pull and too much slack..inspect the bearings for the clutch push actuator and make sure they are not siezed blown out or loose in the case. Also inspect the clutch actuator where it contacts the pushrod and make sure it is not all ground up and material missing. I also have a post documenting what to look for there somewhere in my history.

[El Camexican]

Well I bought some files to file them down flat already they really are not to bad.

Not that this has anything to do with your noise, or clutch feel, but if you are going to file the tabs use a large (at least one inch wide) single Flat file with a medium pattern as fine plugs up to fast. There are waxes available that will help prevent the file from getting plugged up with aluminum, use it if you can.

One face of your outer basket tabs is ed up from acceleration, the other from deceleration. You can tell a lot about how a machine was ridden by looking at which is beaten more than the other. It is more important that you get them fairly smooth as the plate tabs on a new clutch can get hung up in the groves during acceleration and deceleration and that leads to premature warping of the steels. Unfortunately the more you open up the spaces between the tabs the harder the impacts become when you are downshifting to scrub off speed.

If your inner basket is chewed up it is more cost effective to get a new one that it is to try and file it out.

Have fun.

Edit: Forgot to mention that you have to remove an equal amount off each tab, or you'll put all the force on one tab and that would be bad.