99 WR250 - Starts and idles well, but bogs in gear

[Beetle Tag27]

8 minutes ago, shrubitup said:

I would try a new clutch cable and then measure the clutch plates and springs too. You can’t see if the clutch basket is notched? 

I'll open up the clutch assembly later this week and see what's going on. Last time I checked the clutch basket was looking fine.

[ar2stroke]

14 hours ago, Beetle Tag27 said:

I'll open up the clutch assembly later this week and see what's going on. Last time I checked the clutch basket was looking fine.

Did you check the reeds by chance not sure that was looked at?

[Beetle Tag27]

3 hours ago, ar2stroke said:

Did you check the reeds by chance not sure that was looked at?

No, I didn't check the reeds. The bike does not stall when on stand (rear wheel spins free), so I'm suspecting issue with clutch. I'm gonna look at the clutch first and go from there...

[Beetle Tag27]

I did notice that the clutch lever when released does not go all the way back into the groove. There is a gap, as you can see in the picture.

 

[shrubitup]

3 hours ago, Beetle Tag27 said:

I did notice that the clutch lever when released does not go all the way back into the groove. There is a gap, as you can see in the picture.

 

Perhaps too much freeplay which provides for creep on the stand or even at low idle.

 

[Beetle Tag27]

There is zero free play, the clutch is pretty tight. The clutch just does not go all the way into the groove.

[ar2stroke]

On 10/9/2018 at 6:05 PM, Beetle Tag27 said:

I'll open up the clutch assembly later this week and see what's going on. Last time I checked the clutch basket was looking fine.

Any new update?

[Beetle Tag27]

Here is how it looks. When I press the clutch, is this enough movement of the clutch plates? The friction plates seemed a bit worn out.

https://youtu.be/NpZSDJMzQEk

[Beetle Tag27]

I replaced the friction plates and steel plates. When removing the old plates, I discovered that there were 9 friction plates and 8 steel plates. The clutch basket was in good shapel no notches. I replaced them with new 8 friction plates and 7 steel plates. But, the drag is still there. Also, the bike moves when I put it gear. This post describes exactly what's happening to me -- https://thumpertalk.com/forums/topic/570232-wr360-clutch-drag/

I think it has something to do with the cable. I ordered a new clutch cable and will see how it goes.

While waiting for it I will see if switching from 80w to 10w-40 makes any difference.

[Beetle Tag27]

Update: Still waiting for the clutch cable to arrive. I tried 10w-40 oil, but still no luck. The clutch was sticking.

I drained the oil and laid the bike down. I removed the clutch cover to see how the pressure plate moves when the clutch is pressed. I noticed that only one side is moving up, about 1 cm and the other side stays down, it kind of tilts.

I took out the entire clutch assembly and found that there were notches on the outer clutch basket, but not that bad.

I sanded it down to make it smooth and put back the clutch assembly.

Before:

After:

But, still no luck, the clutch sticks and there is drag. I noticed that there were notches on the inner basket too, but it was harder to sand/file it, so I left it as is...

I tried different adjustments at the clutch nut, turning it clockwise and anti-clockwise. No change.

Clutch cable is my last option or I might have to get a new clutch assembly :(