Hi. I have a few questions about a 1985 ATC 250R. Someone gave me this machine and I took the right side(clutch) crankcase cover off because the kickstarter would sometimes not engage. I found that there are two thin washers and a long tube that were missing on the kickstarter shaft and that allowed the large kickstart gear to move out and not engage. I checked a factory service manual and I also noticed that inside the clutch lifter (that slips over the long lifter shaft) there is supposed to be a steel ball. So I ordered the shims for the kickstart and the steel ball and was ready to put it back together. I followed the shop manual word for word and I know I put everything back together right. When I put the steel ball in the clutch lifter and slid the lifter on the lifter rod, I noticed that there is about a 1/8inch gap between the clutch center and the lifter. When I try to install the clutch cover, I make sure the water pump shaft is aligned with the drive pin, but the cover just seems to sit against the clutch lifter and not want to close. Also, where I put the shims for the kickstart doesn't close properly either. I guess this is why the previous owner left them out. Is the clutch lifter gap normal? Keep in mind that the cover has been welded numerous times right near where the clutch lifter sits. Can anyone who knows this engine help me? Thank you very much.

 

1) When assembled, make sure the large kick starter gear is not protruding above the plane of the engine case. If it is, you probably have the main spring improperly positioned.

2) The 1/8th gap is ok. Twist on the lifter lever (where the cable attatches) and make sure it is moving the pressure plate. There should be some free play in the lifter lever when the clutch is released. You can remove the clutch springs, and feel if the lifter lever seems to be doing it's job. Just press the pressure plate against the clutch pack, and twist on the lifter lever to see if it is releasing the pressure plate. It is pretty hard to do with the springs on there unless you use a plier or something to twist on the lifter lever.

 

Thanks for the response. But how will the clutch work when the cover is not installed? Doesn't the long lifter rod go through the entire clutch assembly? I thought the clutch lifter had to sit against the engine case. Thanks.

 

Install the clutch basket, boss, and plates. Then insert the rod, ball, and endpiece. Then, install the outer large pressure plate. At this point, you should be able to press on the pressure plate with one hand, and twist on the lifter lever with the other. The rod, ball, and small pressure end should be inboard of the main large outside pressure plate. The large pressure plate should be forced out by the rod end when you twist the lifter lever toward the front of the engine. If it does, install the springs, tighten incrementally in a criss-cross pattern to prevent breaking the post off the boss.

Take a look at this diagram - http://www.desertunion.com/250r/parts/1986/clutch.htm

 

Thanks a lot! That solves my problem.