86 Honda 250R Clutch Problems

[DickeyDoo76]

I am having some problems with the clutch on my 86 Honda 250R, The clutch went out on it about 1 month ago, I replaced it with a kit from Rockey Mountian ATV the EBC Kevlar Clutch kit. Took it out riding and the clutch was not working!! Brought it back home took it apart and found the ball that goes on the clutch rod was welded to the lifter, I did replace the rod, lifter, and ball, I also found a lot of wear on the engage lever on the other side of the case (the one the cable hooks to) so I replaced that too. But now the problem I cant get the clutch to engage and im all adjusted out of cable, its like the rod is too short? Any I ideas? Thanks for the help....

[wanta86r]

i wouldve suggested buying the 89 update kit. it comes with an improved version of the parts you bought and more for around 60.00 from service honda. did you replace the cable as well?

[DickeyDoo76]

Yea I replaced the cable as well.. At first that is what I thought the problem was is a streched cable but when I hooked up the new cable I still ran out of adjustment. Im still at a loss I have no idea were to go from here?

[Blown 331]

I just had the exact same problem with mine. I thought the rod was to short too, but if you would lengthen it (don't ask) it wont engage. Here is what I did.
You know the bracket that bolts to the left side of the motor that cable attaches to? I drilled a new hole in that and move it forward (away from the clutch lever that goes into the case). This took up a lot of the extra slack in my cable. It still could actully use more slack taken out. I don't know whats up with it. Oh well it works great.

[Jason Hall]

Thats A good Idea Blown 331 I Worked On A 87 250r Quad That Some One Did That To. You Want That 89 Update Though, It Has A Needle Bearing Washer In Between The Outer Cover & Lifter. Sure Sounds Like Something Is Fishy Though, Are You Sure You Got The Washers In The Rite Spots Under The Clutch Basket? Another Thing In 85 & 86 The Races Where The Caged Bearings Rides Where Different One Had A Sholder On It & One Didn't. If Someone Mismatched Parts, That Could Move The Whole Basket In Too Far. Possibly. The More I Think About That, If The Clutch Won't Engage, Then The Rod Would Be Too Long Rite? It Would Be Holding The Cover From Contacting The Disks & Pinching The Clutch. Make Sure The Clutch Rod Is In The Actuator Rite (Where The Cable Hooks) With Clutch Cover Off Put The Ball & Lifter In & Work The End Were The Cable Hooks & Make Sure Its Engaging In The Groove & If It Is I Think You Have A Washer In The Wrong Spot Behind The Clutch Basket. Or The Washer Behind The Clutch Basket Is In You Parts Washer.

[Blown 331]

Does anyone have the part number for the 89 update so I can order it from service honda?

[wanta86r]

you can get your own part numbers at service honda.com

[Blown 331]

you can get your own part numbers at service honda.com

I forgot I would be dealing with a TRX motor and I can actually look that up, doing the "all model" search doesn't work for me. But if anyone has the number or numbers handy I would still appriciate it since I don't even know what parts make up the update. Hard to find something if you don't even know what you are looking for.

[x.system]

22352-kae-770 --piece, Lifter $14.86
22851-ha2-670-- Rod Comp., Lifter $10.35
91001-147-006-- Bearing, Needle, 12mm $6.10

[DickeyDoo76]

I got to looking for that update thinking I should probably do that while it was out and found a kit at nacsracing.com, they sell the hole kit for 60 bucks thats what im going to do... Im going to tear the clutch apart this weekend I had a friend help me do it the first time and mabe he forgot something...Is there anything else that would not make the clutch not engage other than the rod..could a bearring be out some place or the inner cog be wore(where the first clutch disk goes). thanks again for the help people.

[Jason Hall]

The Clutch Basket Has Washers Under It , Make Sure They Are In The Rite Spots. If You Look In A Service Manual You Will See How Everything Goes. If A Washer Is Missing Under It Then The Clutch Might Not Engage, Because The Rod Will Hold The Pressure Plate From Pinching The Disks.

[x.system]

I got to looking for that update thinking I should probably do that while it was out and found a kit at nacsracing.com, they sell the hole kit for 60 bucks thats what im going to do... Im going to tear the clutch apart this weekend I had a friend help me do it the first time and mabe he forgot something...Is there anything else that would not make the clutch not engage other than the rod..could a bearring be out some place or the inner cog be wore(where the first clutch disk goes). thanks again for the help people.

Does your basket have bad grooves in it? If you've replaced everything and its still not working you either have a worn out basket or a part missing. One other thing, count your discs and make sure they are in there right.