I have a 2005 Recon 250es. The gasket on the clutch side started to leak. When I opened it up to replace the gasket I replaced both clutches. I have gone through the adjustment process a number of times but it still slips in the higher gears and at higher RPMs in first and second. Any help would be greatly appreciated.

 

Fairly obvious that you got something wrong when you changed clutches. Take it apart again and check. Not a lot you can get wrong on the centrifugal, but plates in the wrong order, or the back plate "out of bed" is a possibility on the multiplate. De-glaze the plates before you put them back, once they have been slipping, they glaze up. Don't know about the 250 but 350ES had more plates in the clutch than 350 manuals, so did you get the right clutch pack?

 

I have had it apart about 6 times now. Every time I make sure to go by the service manual. One time I even put the original back in and it is doing the same thing.

 

Just possible the shift motor or it's gears are dragging, leaving it partly de-clutched. Doubtful if it is this as I think it would throw a fault when you next changed gear, but if you are sure all clutch components are correct, spring lengths, no big burrs on the basket or centre where the plates rub etc, the shift motor is about all that is left, remove the shift motor and see if the clutch slips, when you change using the emergency lever.