YZ 250 clutch problems

[renes]

I have a 94 YZ 250 and just recently pulled the clutch apart. I had to replace the clutch boss after breaking off one of the spring bolt standoffs. After putting the clutch back together and with the cover still off I tryed pulling the lever to make sure the clutch was disengaging properly and it appeared to work fine. But after putting the cover on and adding oil I started up the bike and found when I put the bike in gear it immediately engaged the rear tire. When the bike is not running I cannot move the rear tire while pulling in the lever in gear. I know I put it back together correctly. I did notice the push rod was a little wore on the non ball bearing end, but the clutch worked fine before I pulled it apart. Any suggestions about what the problem is? Thanks.

 

[overbore]

while its apart you should be able to atleast see some movement
and a gap of mms to show disengagement.Did you put the right amount
of washers back in the push rod that would cause it to not fully
disengage.Some clutches have several washers.Also like others have
mentioned make sure of right amount of disks,not too many would cause
this,and make sure its not hanging up in the basket.

 

[fuzzy]

^ Good point. The 89-93 Clutches had one less plate...

 

[Mr. Clean]

Their should be a small ball bearing between the shaft and the pressure plate. If it fell out the plates will not separate with the lever. Mr. Clean

 

[j_freak]

Before anything else, make sure it is adjusted correctly.