I'm preparing to remove and replace the clutch disks in my 250X and I have a few questions maybe one of you can answer. I don't have the cover off so at this point, all I have is pictures and instructions from the Clymer.

1. The Clymer says the clutch center locknut is "staked" to the mainshaft and that I have to use a die grinder to unstake it. I'm not sure what they mean by "stake". Is it a pin that goes through the nut and shaft? I guess I need to buy a new locknut before I start??

2. Then, once the "stake" is removed, in order to unscrew the clutch center locknut, the Clymer says I can hold the clutch center by putting the bike in gear, remove the chain, and hold the drive sprocket with a clutch holding tool, which I don't have. Why can't I leave the chain on and stick a screwdriver through the top and bottom of the chain, close to the drive sprocket? Won't this hold it? I realize the nut is very very tight.

3. Every thing I read says that the clutch basket, if grooved, can be filed if it's not "too bad". My question is "What is too bad?"

4. Besides new clutch disks, a new clutch cover gasket, and the locknut, are there any other parts I need to do this job?

 

if you look at the nut you'll see that it is bent in at a place on the shaft that is cut out, all it does is it makes sure the nut doesnt back out and loosen. i'v always used an impact gun to take it off. you could bend it back up with a small screwdriver to.

for the basket grooves i think is on your judgement, if they are really deep you could file alittle bit to make it better but it still wont be the smothest. you just dont want to file so much out that there is a ton of play between the plates and the basket.

you pretty much have all the stuff you need to do the job.

 

johnboy, I have heard that using an impact gun also works but don't I <u>STILL</u> have to hold the clutch somehow? Also, are you saying that I don't need to order a new nut? I've seen washers that bend over the nut from behind but I'm not sure I understand how this nut "stake" works. The picture in the Clymer is worthless for that step.
I'm pretty mechanically inclined and can probably do this job without too much of a problem. I just want to make sure of a few things ahead of time. Thanks.

 

Ok, now after looking at the Clymer some more, I am wondering if the nut even <u>HAS</u> to come off????? Can you tell me if I need to remove the nut if I am just replacing the plates?

 

if its just the plates you want to remove, just un do the clutch springs. 4 or 5. i cant remember. the plates will come right out

 

Yes the nut must be removed to change the plates & disks ...

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yea the nut needs to come off....the impact takes the nut off so fast that usally you dont need to hold the basket.when putting it together i use a alum washer between the gears to tighten it down....or if the engine is still in the frame put it in gear and that will work too.