1981 xl250s clutch question

[nixon5000]

hi all

was about to put cover on, realised I may be missing a part?

It was working okay before disassembly, and dont recall this part falling out. so theres a pin,  that slots into outside cover, but not the below part.


http://www.cmsnl.com/honda-xl250s-1980-a-usa_model7691/rod-clutch-lifter_22847428000/#.WGSeuFV96Uk

[TT5 Matt]

It goes between the lifter in the case and the clutch bearing.old fitters trick is to match up the wear marks on parts and that will help you work it out where parts go

[nixon5000]

hmm, maybe im not being clear... the clutch was working fine..with this non-stock looking lifter pin. 

its like the stock..without the longer piece. maybe it was superseded? 

these similar to whats in there so i think will be fine...

http://www.ebay.com.au/itm/1976-XL350-CLUTCH-LIFTER-PUSH-ROD-2-HONDA-XL-350-76-/171424105786?hash=item27e9ac453a:m:mzN69P7dIywj6yIWKIANbzA

http://www.ebay.com.au/itm/1985-Honda-XR350R-Clutch-Lifter-Pin-Push-Rod-/142024190747?hash=item21114d2b1b:g:D1sAAOSwc1FXXwm8

[shelpi]

looks to me like the old switcher roo from another earlier XL, but hay if it worked and no damage or room for inpending doom go for it
Me .... I would put it back to as per std from da factory!
cheers

[nixon5000]

well i think its ok. seems like they used both

[shelpi]

thanx, ya learn something new every day!
cheers

[nixon5000]

hey- well this is strange!

my mate also has a xl250 s, and had a spare clutch pin. But it doesnt fit the outer case, and doesnt slot very far into clutch either?

 is the short pin just meant to press against the inner of bearing? or im missing something that isnt in the above top diagram?

any input appreciated cause im going nuts!!

[nixon5000]

why i assume i have a problem..was when i assembled..the clutch lever at case was super easy..like no resistance.

but it was working great before which is very confusing

[nixon5000]

http://s44.photobucket.com/user/Luke_Ruskin/media/DSC_0271_zpsg1s6lfte.jpg.html
original pin on right..

http://s44.photobucket.com/user/Luke_Ruskin/media/DSC_0269_zpswpvbng4p.jpg.html?sort=3&o=2

[nixon5000]

hanging for some input....free beer?

[80-85 husky]

try a Honda shop to see if no 11 is superceeded? the action of the cable shaft is to convert rotation into push pull. is the shaft. is that dowicki at the bottom of the cable connector shaft moving the clutch separation mechanism far enough?

[nixon5000]

my mates xl250s pin on left, doesnt fit outside cover..or slot far into basket

surely the small pin, on right, which fits cover,  doesnt just press against the inside of bearing? it doesnt seem to even touch though

[nixon5000]

try a Honda shop to see if no 11 is superceeded? the action of the cable shaft is to convert rotation into push pull. is the shaft. is that dowicki at the bottom of the cable connector shaft moving the clutch separation mechanism far enough?

yeah it was working fine before changed clutch plates cause was slipping a little. im sure its something simple im missing but no idea what..

[80-85 husky]

been there and found out why later with any number of issues. can you get a look at another bike? btw xl clutches slip from the factory! usually had to fit Barnett springs or others to try to hold top gear.

[TT5 Matt]

Hi Nixon5000 the parts diagram u show is for xl 20 and 500 clutches,the top diagram for the xl250 with 5 friction plates and the bottom shows the much beefier xl500 clutch with 7 friction disc.if u follow the right diagram im sure it will go back together again no worries