I’ve got a problem. I hope that someone who has had a similar experience would help me out. When I pull the clutch lever in fully, the clutch only partially disengages. For example, with the clutch lever in fully, the bike will stall when I put it into first gear with the throttle at idle. If I give a bit of throttle when I put it into gear, the bike won’t stall but the bike begins to move forward, all with the clutch lever in fully.

While troubleshooting, I have done the following:
1) I have adjusted the clutch lever free play in accordance with pg. 3-9 of our manual.
2) Then I thought that the cable had stretched and I wasn’t getting enough leverage on the arm that connects to the end of the clutch cable. So I compared the movement to that of another 250f and the movement was identical. I am discounting cable stretch.
3) To confirm, I pulled the arm (that connects to the end of the clutch cable) further forward than the cable could pull it on its own. I then put the bike into gear and the engine stalled.

Any suggestions would be appreciated. Thanks in advance.

Do a search on "washer fix" or yz springs. This is common on 01 wr's, but not yz's? spring is "stacking". I changed to yz springs and cured mine. I can't convince my wife we need 1 plane and you have two, and I only want a half dozen seats (or two seats and two dirt bikes broken down behind).

I did the search and found a lot of good info. I bought the washers tonight and will try it tomorrow. Thanks for the help.

I don't own the airplanes, I just get to fly em. You don't want to own one either. Remember the "3F rule"...if it fly's, floats, or fu*ks, rent it because it is cheaper!

They need to rename it the 37 cent clutch fix. I was having the same problem but not as bad as what you described. I was having trouble starting it in gear so when I raced hare scrambles I was next to last off the line. That got old really fast so I bought the 5 washers ($.37) and mic'd them all to .06 inch. (I went through about 30 washers to find 5 that matched the size I wanted) I installed the washers in about 10 minutes and now my bike fires up in gear without difficulty everytime. Best of luck.
Ace

Thanks fellas for the help. I installed the washers and clutch works great. One last question, is this a band aid fix until I rebuild the clutch at a later date? Or was there a flaw in the manufacturing process that is going to require the washers for the life of the bike?

Thanks again.

Or was there a flaw in the manufacturing process that is going to require the washers for the life of the bike

Now thats a good question.