96 YZ250 clutch issue

[@TheBassinBully]

I have been trying to fix this problem on my 94 yz250 for years. I replaced the plates, clutch cable twice, push rod twice, actuator lever twice, and even the ball bearing, and am still having the same problem

[@chadwesleyday]

Theres a bearing suppost to be on the out side of the round thing on end of rod

[@chadwesleyday]

Wish i could take a pic and put.it on here

[@sendcoryanemail]

I just picked up a 96 yz250 and have the same problem. There's a gap between the push rod and the pressure plate about a half inch or so. Seems unlikely the push rod could have worn down that much. Was that the problem for you?

[@flyinhigh450]

Push rod was worn down on mine...

[@grudgeswillbeheld2217]

flyinhigh450 I'm a little bit confused. Was the problem that you pulled the lever and the clutch wouldn't disengage? I'm having a problem like that with my '98 right now. I got a new cable (thinking that was the issue), and I had to adjust it all of the way out before it would even begin to grab. The pushrod is mushroomed over with a sizable impression in the center from the ball bearing.

[@LosTheGamer01]

I’m having the same problem what did you find out that was the problem it could help me thanks

[@Lwmusic1000]

@@LosTheGamer01 did you resolve this issue im having the same problem with my 1998 yz250

[@elcincero321]

Look your bike clutch diagram

[@rickjames4630]

Same exact thing is wrong with my 96 YZ250. I used 2 shims an put them in behind where the ball bearing goes to make up for the slack and it works great. If anyone else has any other ideas please let me know bc ive already replaced the shims once. Thanks

[@calholli]

Just make your shims out of hardened steel and they won't wear....... Otherwise- you likely just needed a new push rod-... they wear out on the ends.... I always pack that ball bearing full of grease... because it's spinning on that push rod anytime the motor is running.... But again--- just buy a new push rod-------- or shim it like a boss. lol

[@pablohiguera8369]

@@calholli hello, how is it shims on this part... i cant figured it

[@calholli]

@@pablohiguera8369 3:20 ... that little puck with the ball bearing inside it--- you just drop a shim down inside it.. and then put your ball bearing back in it....... again, technically t's not supposed to have shims originally-- but if your rod becomes too short because of excessive wear on the ends..... a little shim will help you get more life out of it without buying a new rod........... Now if your shim is too thick-- it won't let your clutch fully engage... which will cause your clutch to slip a lot and end up burning up the discs.. So you may have to experiment with different thickness shims-- depending on how worn your rod is. It shouldn't need it much thicker than a washer. but again, that all depends on how worn your rod is.

[@pablohiguera8369]

@@calholli ok, fully understood, thanks you so much!!

[@calholli]

@@pablohiguera8369 no problem.. I usually throw some grease in there too.. with that ball bearing. I'm not sure how well oil gets down in there.. with it being down inside that puck and the rod in the way-- and always spinning so fast. That's why it wears, because of lack of oil... so little grease will buy you a little time also-- because it's thicker and should stick to that ball longer........................ Because see, what it's doing is------ that rod is trying to push on that plate while it's spinning. That's what the ball is for. To allow it to spin, while the rod does not spin. It's an interesting design-- they could have made it better with a real thrush washer, but just throwing a ball bearing in there is so much cheaper. lol........ It also wears because people never change their gear oil..... keep full synthetic oil in your gear box, and that will also help it last longer.

[@jimster57727]

I had the same problem on my 94 ... my actuator arm was rounded and it dramatically reduced the amount of trow...

[@belizeanaction]

Should the shim be placed before the push rod ? Or just in the space between the ball bearing and push rod?

[@yamaharaptor01able]

I have a 96 yz250 and honestly, I've never had an issue w/it. And the kid ingot it from beat it up pretty good. Maybe i lucked out 🤷‍♂️

[@R4G3DK1LL3R]

You definitely lucked out, I got a 1995 with this issue but I have no ball bearing

[@DigitalAwareness]

add some spacers to the push rod to make it longer

[@DigitalAwareness]

I had this same issue.. I think the push rod wears down and gets shorter. I added a smaller ball to the actuator side just enough to get rid of the gap between the end of the push rod and the pressure plate.. works great now.

[@flyinhigh450]

+DigitalAwareness Thats exactly what it was..Ive already bought a new actuator arm,push rod,ball bearing and pressure plate lifter,clutch is perfect now...

[@dirt-rippers1018]

I need help I've got a 96 as well but the bolts with the springs keep backing out I've tried locktight but do I just make the bolts flush with the cluch or do I tighten them all the way down

[@calholli]

You tighten them down all the way.. But don't over tighten them after they finally snug down... Because you will strip the aluminum threads. You can look up the in/lbs that it should be tightened.

[@dennisharrison3114]

Throw out bearings missing

[@calholli]

no.. that little flat pin with the single ball bearing inside it is the throw out bearing... If you don't keep that little ball packed with grease... it will wear out the ends of the push rod....... so then you have to buy another push rod.. or just pub shims inside that little flat pin... and stack your ball bearing on the shims......... and as your push rod gets wore down again--- just stack another shim in there.

[@TheBassinBully]

@@calholli this is the only solution I've come across thats worked on my yz250.

[@calholli]

@@TheBassinBully You're welcome.. lol

[@paytonemmons4952]

@@calholli what type of shims?? Please help I’m having this same issue🙏

[@R4G3DK1LL3R]

Apparently all of us with yz250’s are having this issue, I have a 1995 the pin don’t have a ball bearing it looks like just clumped up metal

[@codyklein9417]

thank you it helped me out

[@flyinhigh450]

+Cody Klein Yea,it ended up being the push rod..When I got the new one,the old one was quite a bit shorter..

[@codyklein9417]

+flyinhigh450 how much was that

[@flyinhigh450]

+Cody Klein Honestly don't remember but it wasn't alot..I ended up buying all the clutch parts but the push rod wasn't more than $30.00 bucks..

[@LosTheGamer01]

My 96YZ 250 is doing the same thing when I squeeze the clutch it doesn’t engage enough to release it and it looks like my arm could be worn any help will be excellent

[@caseyshirley8906]

Actually that is the wrong pusher hat for that year , that hat goes to 93 to 95s!!

[@travisfuller9603]

i can verify, i just rebuilt a 1993, from my research they didnt change the bottom ends very much, it was the cylinder for the obviously improved powervallve. if you got any more info let me know as im creating essentially a databank for these retro bikes for repair refitment and maintnance

[@anthonydavis4890]

You missing the push rod and nut it goes in the whole your talking is really important for your pressure plate without the push rod your clutch is not going to be working 100

[@coreysmith3615]

theres suppost to be a washer in there

[@frankbatenga3167]

Hey I thought the 97s they don't have a ball

[@newwavepressure6478]

I'm workin on a 2001 is it sup to hav a ball ??