ok I cant figure out what is wrong. First my clutch was hard as hell to pull in so i tried to loosen it. that worked but my bigger problem is no matter how hard or easy it is to pull in the clutch will never ingage, like i hold the clutch in and put it in gear it jumps forward and stalls as if i wasnt even using the clutch at all. what is wrong with my clutch, do i need new clutch cable, plates, or what. I would really appreciate any help, thanks.

 

I would suggest taking the clutch cover off and checking the engaging rod. It sounds like it is stuck or teeth on it are not aligned up properly. Take the cover off and you will more than likely find the problem.

 

I agree with the above, in addition things you want to look for: Any grooving in the "ears" of the basket, a broken fiber disc, and the springs. I had the same thing with my Lt250 and the basket had such deep grooves that the clutch was catching and was real hard to pull, and never totally disengaged. Good luck, let us know what you find.

 

I am about to take the cover off but i never took one off before and was wondering if i do are there goin to be parts springing out or dropping out that i have to watch for. Instead off the clutch ingaging but not releasing all the way it only ingages half way. I wanted to make the clutch easier to pull so i tried fixing the cable but when i did i pulled the engaging rod out and before i fooled around with it it at least ingaged half way but now it doesnt at all. Maybe when i put the engaging rod in i put it in wqrong or somethin but im about to take the cover off so ill get back to you and give you the results. Thanks for the info.

 

When you remove the cover, just a few hints. Drain the oil, sounds like a no brainer but I forgot once...ONCE what a mess! Drain the coolant by removing the hose on the water pump. Remove the foot peg on the clutch side. Remove the pin and flip the brake lever back. Remove the kick start lever, remove the clutch cable..now here is a few things that may help here...loosen the adjuster on the bars, then remove the bolt that holds the aluminum lever to the shaft that goes into the clutch cover(hint the lever will not come off unless the bolt is removed), pull it up, may require some GENTLE prying with a flat screwdriver, then you can back off the threaded piece still attached to the clutch cover. remove all the bolts/screws holding the clutch cover on. I usually put them in a cup or something to keep track of them. Try to pull the cover off, most of the time it takes a few GENTLE taps of a wooden/rubber/plastic mallet to get it to break free. Do not hit with a metal hammer or pry at the gasket surface. There are NO parts that should come flying out, or dropping out. The clutch should have a small piece sticking out that has notches that corespond to the shaft in the cover. (When you put the cover back on you have to put the grooves to the back of the engine.) You can see if the basket is worn without any further disassembly, just look at the ears, if there are deep, read anything over 1-2mm, it is time for a new basket. If not the problem is probably not with the actual clutch, but the shaft or cable. Hopefully when you pull it apart there are no pieces of stuff in there, cross that bridge when you get there. To put the cover back on use a new gasket. Use blue lock tight on anything threaded. With that part sticking out of the clutch put the grooves to the back of the engine. Rotate the crank shaft so that the flat part that turns the water pump is straight up, then on the cover you will see how it fits into a groove, rotate this so it too is straight up.
Just in case something is stuck or wedged in the clutch shaft of the cover, see if it rotates freely...if not there is a retaining nut by where you removed the aluminum lever that holds the cable. Remove it and pull the shaft out with a pair of plyers, spray carb cleaner in all areas to remove any junk, use some grease and reasemble. Now put the cover on, while pushing it home, turn that same shaft to engage the piece sticking out of the clutch, I think it is clockwise? It should seat easily, if not make sure the water pump is engaging if not rotate it a little one way or another. Put all bolts in, they should stick out about 1/2 inch if not you have them in the wrong hole. Tighten in a scattered pattern like doing a wheel on a car. Not super tight, but snug. Finally, turn the shaft of the clutch so it is fully engaged and then put the aluminum lever at about 11:00 if 6:00 was pointing at you, put in the bolt that tightens it, and snug it. The rest you can figure out. If not write and I'll respond.