northbiker

i need a diagram for a clutch besides the one in clymer. the exploded view doesnt give me enough details to let me know how the parts go together. oh and does anyone live in utah that might have a clutch removal tool for a 86 rebel 250? i dont have time to wait to get one in and the shops wont let me rent one for a one time use. oh and the nut that takes this funky tool... can i replace it with a regular hex style nut or is there a good reason to keep the stock one that takes a stupid tool?

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flitecontrol

Not sure if the same tool fits all model years. I made a tool by cutting down an appropriate size socket with a Dremel tool cutting wheel. In talking with a guy who works on these clutches all the time, he cuts out the staked (bent down section of the skirt on the nut) part of the nut and uses an old screwdriver blade and hammer to loosen the nut. Forgot to ask him how he torques the new nut to specs though. If you can get something to fit under the stake and lift it out of the slot, you can probably reuse the nut. A new one cost me around $3.50 at the Honda stealership. Due to the clearances on the clutch and the need to lock the nut in place, you pretty much have to use the special nut.

If you go to cheapcycleparts.com or ronayers.com, their clutch diagrams are usually pretty clear. Remember, it comes apart the way it went together, if you remember how that was.

Soak the new friction plates in 10W-40 oil or whatever you use in the crankcase for several hours before installing. Take the glaze off the metal plates with sandpaper before reinstalling. If any of them are bent or badly worn, replace all of them.

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I'm keepin' all the left over parts. I'm gonna use 'em to build another bike!

2001 Rebel 250, 1989 Vulcan 750
Putting your bike info in your signature helps others help you!

mavreix

Im curious to know what tool did you end up using to get the locknut back on? Ive got a socket thats 27mm so its close to the right size but I would definitely have to dremel it to get it to fit all the way on. and right now im at a loss how to get this thing torqued back on

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flitecontrol

Yes, to get a standard socket to work, you have to cut it down so there are extensions (look like the turrets on a castle) that will fit the slots on the lock nut. Think I used a 7/8" and had to file down some of the inside to get it to fit over the nut. Could have cut the extensions longer, but wasn't sure they could withstand the torque if I made it that long.

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I'm keepin' all the left over parts. I'm gonna use 'em to build another bike!

2001 Rebel 250, 1989 Vulcan 750
Putting your bike info in your signature helps others help you!

wickked1

Here is an exploded view of the 86 250 clutch
http://www.bikebandit.com/houseofmot...rebel/o/m10724

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Fat guys on little bikes,
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Buickguy

I've got the parts fiche for that. I don't know if that would help you but I could email it to you if you'd like.

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