I have a 85 250es big red. I just replaced the clutch cover gasket and now the gear shifter sticks. If I leave the clutch cover bolts loose it shifts fine but soon as I tighten them it sticks. I tried adjusting the clutch adjuster and it locks the shifter solid. I have a manual and had it apart several times and back together as the manual shows. I can't figure this out. Any ideas on what I am missing???

 

Did you put an honda gasket back on? did you drop washer on shifting arm? did you align the shift lever up with the ping dots?

 

It's a aftermarket gasket kit I got off eBay. It was together with just gasket maker before and it shifted fine. The washer is on the shaft and I aligned the punch dot. Did it probably 10 times or more with the same result. If I leave the case bolts slightly loose it works fine

 

It does sounds like an thickness problem in gasket if you did all that was said...I know you said had sealer gasket before...Can you measure the gasket thickness? Think ,015 is what honda wants...Also will atv shift thru all the gears fine with bolts loose? Did readjust clutch before you tookdown? also where is the adjustment now?Is your reverse assit lever in correct spot?

 

The first time I assembled one of these I got it wrong and the back inner clutch plate was not sliding onto the pressure plate (the one with the 4 bosses with springs round them). This had caused the back inner plate to bend.