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XR250R Clutch Problem

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Quote Me Happy



Joined: 15 Jan 2005
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PostPosted: 10:10 - 04 May 2008    Post subject: XR250R Clutch Problem Reply with quote
Hello chaps,

I think the clutch has gone on my XR. For a while now it's been getting harder and harder to find neutral and last weekend when in neutral the bike jumped into gear without me touching anything.

On my way home I had problem changing gear - going for a gear and it not selecting, going for the shift and it staying in the same gear.

Also, it wouldn't free wheel in gear with the clutch pulled in.
Had a look at the clutch cable and there was a fair bit of play in it by the engine so adjusted that so it was tight and it made no difference.

The oil level should be OK as I checked it last weekend.

Anything else I should check before going for the clutch plates?

Cheers.
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Quote Me Happy



Joined: 15 Jan 2005
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PostPosted: 18:45 - 04 May 2008    Post subject: Reply with quote
Well I've put in a new clutch cable and that made no difference, time to have a look at the clutch?
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G
The Voice of Reason



Joined: 02 Feb 2002
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PostPosted: 18:58 - 04 May 2008    Post subject: Re: XR250R Clutch Problem Reply with quote
Jumping into neutral on it's own seems a bit odd for clutch plates - similarly, generally you can clutchless shift fine if they are either too tight or too loose.

Not freewheeling in gear with clutch in sounds like clutch plates sticking or a bit of dodgy adjustment on the cable etc.

So, err, to conclude... I don't know. But you were looking awfully un-loved replying to your own thread, so I thought I'd show that at least somebody had read it Razz.
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PostPosted: 19:02 - 04 May 2008    Post subject: Re: XR250R Clutch Problem Reply with quote
G wrote:
Jumping into neutral on it's own seems a bit odd for clutch plates - similarly, generally you can clutchless shift fine if they are either too tight or too loose.

Not freewheeling in gear with clutch in sounds like clutch plates sticking or a bit of dodgy adjustment on the cable etc.

So, err, to conclude... I don't know. But you were looking awfully un-loved replying to your own thread, so I thought I'd show that at least somebody had read it Razz.


Laughing Cheers G.

I've got a bad feeling it's something gearbox rather than clutch as it should have clutchless shifted fine with no clutch.

I can see this getting tricky.
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smeg918
Derestricted Danger



Joined: 04 May 2008
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PostPosted: 19:21 - 04 May 2008    Post subject: Reply with quote
Hi, your problems in the gearbox poss the selector forks or selector drum, sorry to be the bearer of bad news. Hope you get it sorted soon without it being to painful (financially). regards smeg Smile
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PostPosted: 08:50 - 05 May 2008    Post subject: Reply with quote
smeg918 wrote:
Hi, your problems in the gearbox poss the selector forks or selector drum, sorry to be the bearer of bad news. Hope you get it sorted soon without it being to painful (financially). regards smeg Smile


Just remembered, the bike was dropped onto the left side at walking speed. It bent the gear lever in towards the engine casing so that the lever scored the casings with each shift.

Looks like it's bent something in the 'box.

Even if it is a bent piece in the gearbox, shouldn't I still be able to freewheel it in gear with the clutch in?
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smeg918
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Joined: 04 May 2008
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PostPosted: 09:23 - 05 May 2008    Post subject: Reply with quote
Hi, yea as you said even if it was stuck in a gear with the clutch in it should freewheel. Sounds like the clutch is not disengaging, though that shouldn't cause it to jump in or out of gear, could be you've got a couple of problems. Not to sure of the set-up on the xr but if the cable operates a lever on the opposite side of the engine from the clutch then there will be a push rod going through the engine, check to see if that still operates smoothly.

Last edited by smeg918 on 09:29 - 05 May 2008; edited 1 time in total
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PostPosted: 09:29 - 05 May 2008    Post subject: Reply with quote
smeg918 wrote:
Hi, yea as you said even if it was stuck in a gear with the clutch in it should freewheel. Sounds like the clutch is not disengaging, though that shouldn't cause it to jump in or out of gear, could be you've got a couple of problems.


Thinking about it - I'm not sure if it jumped into gear or just lunged forward and stalled while in gear but with the clutch pulled in.

I think it's a case of getting it apart and having a look now.
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PostPosted: 09:38 - 05 May 2008    Post subject: Reply with quote
smeg918 wrote:
Not to sure of the set-up on the xr but if the cable operates a lever on the opposite side of the engine from the clutch then there will be a push rod going through the engine, check to see if that still operates smoothly.


The cable comes down the bike clutch-side

https://img.photobucket.com/albums/v619/baldgit/clutch.jpg

And the bit it attaches to is moving up and down freely.
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smeg918
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Joined: 04 May 2008
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PostPosted: 10:12 - 05 May 2008    Post subject: Reply with quote
Nope no push rod there, that works of a worm drive. As you say I think it's time to get your hands dirty. Looks easy enough to get at though. If the clutch is not disengaging your problem should be under that engine cover. Happy hunting Smile
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PostPosted: 10:14 - 05 May 2008    Post subject: Reply with quote
smeg918 wrote:
Nope no push rod there, that works of a worm drive. As you say I think it's time to get your hands dirty. Looks easy enough to get at though. If the clutch is not disengaging your problem should be under that engine cover. Happy hunting Smile


Just ordered a Haynes Manual in preparation Laughing
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