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250ex clutch questions

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Brand new to the forum this is my 1st post. I have seen several other posts about this issue on here, but seems no one ever comes back and posts their resolutions

I have owned this particular 04 trx250ex since it was new, it has never been used lightly. But the clutch just started to slip, at first it was just sometimes. Then one day just nothing forward happened when i got on it. It was running so I checked a few things a while later it was warmed up and seemed to work good. (I was pushing snow)

It degraded quickly over the next few days but now nothing.

I have pulled it apart and replaced the centrifugal clutch pack with a caltric pre assembled pack. Also replaced the friction plates, pads and springs on the disk clutch with I think dp clutches.
But alas still nothing forward happens, forward was my favorite thing that this would do.
The slop adjustment on the auto clutch doesn't seem to make a noticeable difference at anything.
It shifts through the gears ok, but it feels different than it used to, there was a more clear difference in the shifter feel when the clutch would disengage,
it has a pulling surge like it wants to go and like others have mentioned reverse has more pull but no actual moment either direction.
I soaked the clutches even though it said it wasn't necessary.

So my questions:

1- What the hell?

2- I didn't do the clutch drum on the centrifugal clutch it measured 116.5mm which is the service limit 馃 is that the hell maybe?

3- Is it possibly some sort of hidden gremlin in the shift linkage? I notice my center shaft on the lifter cam that the ball retainer rides on has groves in the center like the little spring has been hanging up or something

I just wanna ride and such and stuff so lend me you finger clicking ideas together we stand divided we fall.
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Welcome to the forum

[QUOTE="Bonefu, post: 62243, member: 35768"
So my questions:

1- What the hell?

2- I didn't do the clutch drum on the centrifugal clutch it measured 116.5mm which is the service limit 馃 is that the hell maybe?

3- Is it possibly some sort of hidden gremlin in the shift linkage? I notice my center shaft on the lifter cam that the ball retainer rides on has groves in the center like the little spring has been hanging up or something

I just wanna ride and such and stuff so lend me you finger clicking ideas together we stand divided we fall.
[/QUOTE]

First lest start with start with what is adjustable and what's not:

The external adjustment on the cover is for the manual clutch.- the centrifugal clutch has no adjustment and the sprag clutch only works in one direction.

The sprag clutch locks up under deceleration to provide engine braking and will allow the vehicle to be push started.

The centrifugal clutch has a very narrow rpm range between unlocking, slipping and locking.

Above about 2500 RPM the centrifugal clutch is fully locked - if there is any slippage above that, it's the manual multi-plate clutch that is doing the slipping.

So in most cases, it usually comes down to improper adjustment of the manual clutch release, improper assembly of the clutch or the use of non-approved engine oil.

You say you replaced the plates - did you replace the driven metal plates or have them reconditioned before assembly? Did you install new clutch springs? What kind of oil did you soak the plates in? Was it a JASO rated oil and are you using the same oil in the engine?

I'll go out on a limb and suggest the manual clutch release was not assembled correctly.

The clutches have nothing to do with shifting except to protect the transmission from improper shifting. As the shift lever is operated, it releases the manual clutch disconnecting the engine from the transmission, so whether shifted normally by letting off the throttle and shifting or abnormally with the throttle held wide open, the crankshaft is disconnected from the transmission input shaft. I'm guessing that in one fashion or another, the clutch release is holding the clutch in release
I used a whole clutch kit, friction pads, new drive plates and springs. I use Honda gn4 oil and that's what I used to soak them.
I have no motion at any rpm just as it was before replacing anything. It feels like it is stuck clutched.
Drive plates are fiber and the driven plates are bare metal

I just checked the service manual to see if it detailed any timing of clutch hub to the pressure plate. It did not, so I will presume the pressure plate is omni-directional.

OK, so how did you assemble the clutch? The best method I have discovered is to place all the plates onto the hub (#5) - with all the plates installed place the pressure plate (#8) onto the hub assuring the splines on the pressure plate engage the splines on the hub (on some clutches alignment only occurs in one position) - put two springs in place and use a flat washer on the bolt to hold the spring in place - only tighten the spring enough to hold things together but loose enough to be able to move the tabs on the driven plates to align the tabs with the slots on the basket (#1) - when the hub has been aligned to the transmission shaft and the hub fully installed into the basket, tighten the retaining nut - remove the bolts from the springs, put the other two springs in place, put the lifter plate (#9) in place and proceed to install the spring bolts tightening each bolt a few turns at a time until the springs are compressed and the bolts are bottomed out - tighten the bolts to 8 to 9 foot lbs (96 to 108 inch pounds) - install the centrifugal clutch bell (#17) and the sprag clutch (#27) - at this point, put the transmission in gear (any gear) and rotate the rear wheels forward - if all is assembled correctly, the clutch should turn the crankshaft. Do this and you are now assured the manual clutch is connecting the transmission to engine.

I don't think you can install the centrifugal clutch incorrectly unless you disassemble it and invert the shoes (#18)

BTW - GN oil is as good as any you can use

4508
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" (on some clutches alignment only occurs in one position) "

this was the problem, I thank you for your patient help. The pressure plate and clutch center were stacked instead of meshed I hope others can find this to also be their problem
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