[tyrisis]

Well thanks to the help of several members I found the clutch on the other side of the Quad!!!

Found 2 things that stood out to me let me know what u think

1. 1 of 4 screws on the clutch is un threaded 2 - 3 turns... (I am assuming this is bad) Please see pic.

2. shifter shaft on this end is not lined up with timing mark. ( could this have happened haveing the other side case off)? again see pic.

also do i have to take off the clutch on the right to get the fiber/steel plates out?

is this nut on the one on the right reverse threaded?

also i found a washer in the case when i pulled it off any ideas where it might go...

Thanks

Tyson

 

[Helmut]

1. 1 of 4 screws on the clutch is un threaded 2 - 3 turns... (I am assuming this is bad) Please see pic.

Yeah, it should be tight. That's what holds tension on the fiction discs and plates.

2. shifter shaft on this end is not lined up with timing mark. ( could this have happened haveing the other side case off)? again see pic.

Yes, if you let the shifter shaft pull out a little, when the other cover was off.

also do i have to take off the clutch on the right to get the fiber/steel plates out?

is this nut on the one on the right reverse threaded?

Yes, the centrifugal clutch has to come off before you can take the clutch plates out of the other clutch. And yes the nut that holds the centrifugal clutch on has left hand (reverse) threads.

also i found a washer in the case when i pulled it off any ideas where it might go...

Either on the reverse lockout shaft or on the clutch lever.

 

[shadetree]

agreed^^^^ on all of what hemut said..look's like he's got you covered...all except the nut part on the clutch disk..helmut..the reg clutch fiber disk only uses right hand threads..this is what he asked..take the nut off like you would any other nut.

 

[Helmut]

agreed^^^^ on all of what hemut said..look's like he's got you covered...all except the nut part on the clutch disk..helmut..the reg clutch fiber disk only uses right hand threads..this is what he asked..take the nut off like you would any other nut.

No, I believe he asked about the nut on the centrifugal clutch, he said the one on the right. I think he just left out the comma between the words right and reverse.

is this nut on the one on the right reverse threaded?

 

[shadetree]

agreed^^^^ on all of what hemut said..look's like he's got you covered...all except the nut part on the clutch disk..helmut..the reg clutch fiber disk only uses right hand threads..this is what he asked..take the nut off like you would any other nut.

No, I believe he asked about the nut on the centrifugal clutch, he said the one on the right. I think he just left out the comma between the words right and reverse.

is this nut on the one on the right reverse threaded?

ah..ok..then yes..that one is left hand threads then..my bad..lol

 

[tyrisis]

Thanks guys, And yes looking for the nut on the centrifugal clutch.

 

[shadetree]

Thanks guys, And yes looking for the nut on the centrifugal clutch.

your welcome..yeah..centrifugal clutch nut is left hand threads..which means turn's clockwise to take off..counter clockwise to put on..lol.

 

[shadetree]

the reason the centrifugal nut tightens counter clockwise..is because that clutch turns clockwise..which helps keeps the nut tight at all times, and on the clutch pack disk..it turns counter clockwise...and this keeps the nut tightened on it at all times...i'm sure i'm correct on this..unless i got alot older over night ??..< shush helmut >..lmfao.

 

[Helmut]

the reason the centrifugal nut tightens counter clockwise..is because that clutch turns clockwise..which helps keeps the nut tight at all times, and on the clutch pack disk..it turns counter clockwise...and this keeps the nut tightened on it at all times...i'm sure i'm correct on this..unless i got alot older over night ??..< shush helmut >..lmfao.

Yeah, it keeps the nut from backing off, or at least, that's what I figured.

 

[tyrisis]

Is there a way to test the centrifugal clutch? On or off the quad?

Thanks
Tyson

 

[shadetree]

Is there a way to test the centrifugal clutch? On or off the quad?

Thanks
Tyson

other than mic'ing it for the springs..arms..no..there is no test you can do while it is off the motor..as for on it..only way to test it..is to run it ..lol..which means..all together..and ridding it..thats about it.

 

[tyrisis]

Or not ridding it... depends if thats my issue.. Thanks for the help will keep u posted with end results..

 

[tyrisis]

Well I think i found the issue, The clutch plates (steel) are susposed to be flat correct!!!

It appears the last person to do this job ether tightend the basket on with out seating it correctly or...

Is there a way for the clutch to losen and slip and do this on its own..
There was one screw loose on the clutch springs.

Went to the honda dealer, They had 1 plate in stock... but not the same... It matched up size thickness and notches, but was lighter they advised this should be ok.

so all back to gether just waiting on silicone to dry then see if my toy works.



Thanks for the help guys

 

[Helmut]

It appears the last person to do this job ether tightend the basket on with out seating it correctly or...

Yes, someone put that back together wrong. I don't think there's anyway it could have loosened up and bent those plates concave, like in the picture. It had to be put together wrong to begin with. By looking at the first picture, it looks like they didn't have the clutch pack seated all the way down in the basket when they tightened the 4 bolts. That bent plate tells me they didn't have the notches lined up right and it didn't go all the way in. That one plate was what was keeping it from going all the way in like it's supposed to.

Went to the honda dealer, They had 1 plate in stock... but not the same... It matched up size thickness and notches, but was lighter they advised this should be ok.

As long as it's the same thickness, weight won't matter.

 

[tyrisis]

Hey guys,

Well I got it back together... No leftover screws or anything.. and no difference in performance.. Well acctually when in gear it does not move at all.. The tires dont spin when picked up.

The neutrel light stays on at all times, Is there a possibility of a safty switch? any other ideas?

Thanks

Tyson

 

[Helmut]

Hey guys,

Well I got it back together... No leftover screws or anything.. and no difference in performance.. Well acctually when in gear it does not move at all.. The tires dont spin when picked up.

The neutrel light stays on at all times, Is there a possibility of a safty switch? any other ideas?

Thanks

Tyson

I wonder if it's actually going into gear? I wonder if the shift drum is turning, because the part that makes the neutral light come on is bolted to the end of the shift drum. I would pull the left side cover off and check the shifting linkage and see if the shift drum is actually turning when you try to shift. But before you remove the left side cover, try adjusting the clutch free play. If the clutch free play isn't adjusted correctly, it can cause the ATV to not pull.

If the linkage is working and the shift drum is turning and it's going into gear, the other clutch (centrifugal) could be bad.

 

[tyrisis]

I am pretty sure its shifting... just not engageing... Could the centrifugal clutch be stuck?

It did sit for many years... mabey just needs to be released? Pull the arms up with a pry bar?

 

[Helmut]

I am pretty sure its shifting... just not engageing... Could the centrifugal clutch be stuck?

It did sit for many years... mabey just needs to be released? Pull the arms up with a pry bar?

Yeah, it's a possibility if it's been sitting for a long time.

 

[tyrisis]

Hi again

Well i have it apart again the centrifugal clutch has 5 groves around the out side where the sliders stick out... now this is metal it doses not look like its too far warn though.

the one way bearing seems to be working ok.

now the clutch... should there be pressure on the disks at all times or should they have free play when in the basket? theres 5 disks and all have good 1/4 inch movement between them..

What should i look at to see if they tighten up?

It seems to be going into gear if i tighten the freeplay right up rev it a bit and snap into gear quad jumps forward ( not far enough to move it..) but just a lurch forward and if you take the weight off the back ( tires in the air) wheels move according to gears. ( forward/backward) however the green neutral light never goes out and the reverse light is on when in neutral and goes out in all gears...

any other suggestions?

THanks

Tyson
(would any pics help)

 

[Helmut]

Well i have it apart again the centrifugal clutch has 5 groves around the out side where the sliders stick out... now this is metal it doses not look like its too far warn though.

A real shallow groove is normal there. If it's deep, it might be a problem.

now the clutch... should there be pressure on the disks at all times or should they have free play when in the basket? theres 5 disks and all have good 1/4 inch movement between them..

This is where your problem is I believe. They should be held tight together. The 4 bolts and springs are supposed to hold tension on them, so as not to slip. Sometimes one of the plates will get jammed and the disc and plates won't go all the way in the basket. Either that, or you're missing a plate or disc. I believe the 250 is supposed to have 5 fiber discs and 4 metal plate. If you have these, then one of the plates must be jamming and the clutch pack isn't going all the way in. I would take it apart and reassemble it. This is a common thing to happen. Before I take one apart, I always notice how high the clutch center sits in relation to the top of the clutch basket so I can be sure it goes all the way in the basket. Of course, you couldn't do this because your clutch wasn't right to begin with.

the green neutral light never goes out and the reverse light is on when in neutral and goes out in all gears...

I would check the neutral wire and the reverse light wire where they plug onto the neutral switch and the reverse switch. They are located side by side and someone may have put them on wrong. I don't know why the reverse light would stay on all the time, though, but that would probably fix the neutral light. If that's not the problem, the part that bolts to the end of the shift drum that operates the lights might be messed up.