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

http://cdn.cheapcycleparts.com/images/HO/14HA2FE1/HA28E0400.png

[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??

134713

[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

[rjs89ia]

65 is a steal for that kit your lucky i didnt see it first lol, ive got one on one of my engines and you'll definately feel a difference your hand wont get as tired from pulling the clutch all the time and its really smooth. It helps to have an aftermarket clutch perch and lever too, ive got one with multiple adjustments so it suits my riding style.

[SteveCZ28]

Well I have huge hands so it doesn't bother me to pull the clutch in or hold it. Also will I really gain that much by going to an aftermarket perch and lever? Can u show me what u use?

[SteveCZ28]

well i got my 89 upgrade kit the other day. installed it last nite. and now i FINALLY have a working clutch! lol now i just need some timee to take the bike out for a spin before snow flies here