85/86 250r clutch question help!

[BAN ONE]

in the process of putting my 250r motor back together and run into a problem. as stated in the manual at the end of the clutch rod there is supposed to be a ball

http://i997.photobucket.com/albums/af100/banditatc70/rman.jpg

when i took it a part there was no ball. so i ordered one and now when the ball is installed it will not let the lifter go in far enough and makes the plate stick out

with the ball out
http://i997.photobucket.com/albums/af100/banditatc70/rmotor.jpg
http://i997.photobucket.com/albums/af100/banditatc70/rmotor5.jpg

with the ball in
http://i997.photobucket.com/albums/af100/banditatc70/rmotor3.jpg
http://i997.photobucket.com/albums/af100/banditatc70/rmotor4.jpg

is it possible that someone has the wrong clutch rod in the motor? this thing is starting to get on my bad side haha

[3wheelrider]

It appears you have a 89' updated clutch- it doesnt use that single ball bearing.

[JohnR.]

Its been a while since I fooled with mine but there was an update kit for the clutch and if memory serves me correctly it eliminates the ball because the needle bearing you have on the end of the rod will perform the function that the ball used to. Look at the clutch diagram for the 1989 TRX250R and compare it to the ATC. I think someone may have already done the update on yours so the ball is no longer needed.

John

[BAN ONE]

ahhh! okay that makes a little more sense then.. i will check the diag. of the 89. thanks for the info!

went to service honda and checked the diagram and that looks to be what it is.

[Dirtcrasher]

Another confirmation, you have the 89 update kit, no ball. The ball was one of Hondas very few mistakes........ :D

[JohnR.]

For the record, I had zero troubles with the original 85 setup but I was tearing into it to do the billet basket anyways and had the update on the shelf. I went back to stock clutch springs while I was in there and would recommend against heavier springs like I had used. Even with the 330 kit and a clutch with a lot of years on it I have no slippage problems with the stock springs. All I ever got from the stiffer springs was a tired left hand.

[bigbadktm]

makes you wish you had a hydro clutch with those tougher springs doesnt it

[JohnR.]

Yes and no. No need for the extra expense or complication of the hydraulic set up when the stock springs with good plates get the job done. Probably less wear and tear on some of the other clutch mechanism with the lighter springs as well.