I recently took apart my 86 ATC250R motor to fix my kick starter and noticed something interesting. The push rod that opens and closes the clutch and clutch lifter (what acutally pushes on the pressure plate) were seized together. There is a ball bearing that is supposed to be in there. The ball was ground down and welded the rod and lifter together.

Here's what I found out. I was looking in the service manual and saw that they had 2 setups for the clutch. I wanted to upgrade to the 88-89 style setup which has needle bearings and a slightly different pressure plate. I went to the dealer and Honda actually makes a kit for it. It's the 89 upgrade kit. I'm impressed! Honda actually makes a whole kit to fix this problem. It only costs $62 and you get a new pressure plate, push rod, clutch lifter and needle bearing.

Just though I'd share a cure for one of Honda's design faults. I hope this is helpful.

 

Thank you for posting that!
I asked on this forum a few months back about this kit. I had heard about it somewhere. My dealer didn't have a clue so I gave up. Do you have the part number?

 

The part number is: 06220-HB9-305

 

Thanks a bunch.

 

I had the same problem with my clutch!, I bought the kit and fixed it and then i made a latex boot to fit over the moving parts and packed it with bearing grease and haven't had a problem since!