1996 Honda XR250R Clutch Replacement 

I have heard that since I posted the video. I will do that next time.

Thank you for that advice. I just recently heard about the soaking the disks. I will make sure to do that next time I’m doing any clutches.

Yes you don’t lose oil that way. Makes things easier.

an impact is going to be your best bet. If you don't have one, you should be able to grab onto a shaft or the clutch basket or something with a wrench. It might be a little harder but that is what you will have to do without an impact.

I have another video on this bike that might help you. Watch the beginning and you can see how it should look. If you still need more help let me know and I will get you some pictures or something.

I have a 98xr250 just changed my clutch out today. When u slide that arm back in the case thru that hole there is a spring it goes thru also at least on the 98 models. But for some reason my arm still doesn’t act rite. Your video was definitely helpful

The return spring is just those 4 clutch springs on the clutch pack. Those force it against the case. So a previous idiot mechanic had butchered mine. It had pieces missing. But the thing I found that helped the most was on Honda Parts House they have parts diagrams. Take everything off the shaft and put it together piece by piece strictly according to that diagram. I thought I was seeing everything but that method made me realize what was missing and I finally got it all together.

I’m talking about the spring that goes on the clutch arm.

When I look the part up it’s called spring clutch leaver it’s a 2$ real small spring. I believe mine is messed up

So I’m pretty sure that bike is missing the spring so I’m wondering how well it worked

Thank you. I appreciate you watching and the feedback.

At that time I am explaining missing parts. I used a manual on HondaPartsHouse.com with exploded diagrams.

I’m not sure I understand the question. But I would rather use a standard clutch than the clutches that do the work for you. But I am old school and prefer to shift gears myself. I think you can control gears better for the situation you see coming than an auto clutch or something.

I’ve only had the chance for one weekend of riding. Probably 150 miles or so. But I noticed no difference in the pull and they seem to be doing great. One of the last trail was a really rough, very steep, rocky hill climb and it held up great to me giving it all the beans. I have no complaints at all.

They bottom out and stop. I would just recommend torquing them down to right about enough. Once bottomed out the springs will be right where they need to be.

@@micalstephenson do they need to be bottomed out. My clutch mushroom thing is not even contacting the actuator part. The clutch it’s not working at all here

Yes those do bottom out. If you end up with a small gap then I would make sure you have all the washers and parts in place. Look at a parts diagram and follow it meticulously because it’s real easy to miss something. If there is still a gap then something isn’t right. Maybe things are just perfectly aligned or something along that line.

I believe the torque setting for a 6mm bolt is anywhere from 9-11ft-lb.