RM 250 Clutch noise 1986 (Yes an old girl I know)

More information please. What EXACTLY is it doing? Slack clutch lever? Stuck clutch lever? Crunching or grinding as you try to shift? Grabbing and stalling as it selects the gear?
Start at the clutch lever. Check it is pulling the cable then check at the transmission end that the cable is connected and moving with the lever. Next check the lever on the actual transmission. Does it seem too tight or too slack? These will give clues as to where the issue could be.
It's a 37 year old bike so is it the original Clutch? Even motorcycle clutches wear out.

If it's cable actuated clutch, the cable may have snapped, which is also indicated by the clutch pedal dropping to the floor or becomes lighter to press. Check at the transmission bell housing, the clutch lever may have been broken or bent. If it uses hydraulic system, the slave pump may have been dislocated, at the transmission side.

Hi, sounds like the friction & metal plates in the clutch are stuck together. Has the bike sat for a while? If so, the clutch might free up if you get it started, roll along and put it in first, then get through to 4-5 gear, and holding the clutch in, accelerate & back off the throttle. Sometimes this will free them up, but careful to do it somewhere large enough. If the right type & amount of oil are in the gearbox (4 stroke car or bike engine oil that doesn't have friction modifiers in it), take the oil fill plug out 7 use a light to look at the ckutch basket. If you can see it, you should be able to pull the lever and see the pressure plate move outwards slightly. Good glycol coolant should do the job, straight coolant should be fine around 500ml. Hope this helps :)

Synchronize the carburetors. Carburetors that are out of synchronization will cause the clutch and primary chain to rattle.

The bearing for the clutch outer drum may be worn. The adjustment on the handlebars is to set lever free play(about 1/2 inch) before the cable becomes tight and operates the clutch release inside. Make sure the outer drum cover is tight--check with the clutch lever to make sure the plate releases the disks and plates.

You use normal engine oil in the engine(SAE 30).DO NOT use gearbox oil or clutch fluid as you will get problems with your clutch.

Please leave a fair comment if you feel I have helped you.

Thank you

First, try the cable adjustment at the lever end, if no more movement re-adjust inwards, then adjust at the clutch end.
If no joy, then it is either the lifter mechanism or the clutch its self.
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Bike-Doc

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What type oil in your crankcase? Wet clutches go on strike with wrong oil. Engine oil is a no no.

Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock. www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx

Look at the clutch diagram on the Babbit's site. Chances are that the "E" ring #14 was not put on the clutch rack #13 that the pinion shaft #16 engages to pull the pressure plate #8 outward, disengaging the clutch. Without the E-ring the rack can fall inside the clutch and is unable to pull the clutch plates apart. This is likely to be where the problem is. By the way, look at the sequence all the parts are to be installed in. Does your clutch assembly match that sequence? Let me know what you find.

I don't get paid for my answers. I am only trying to help. I do take pride in them. So if you will, > > > > A “very helpful” rating for this answer? Thanks

1) Can you push the bike while it's in gear with the clutch pulled in? [If so, clutch is disengaging OK]

2) If not, check when you pull in the clutch lever that it pulls all the way through to the actual clutch [If not, replace broken clutch cable]

3) If so, clutch is binding. Either fix it properly by stripping the clutch.. or just brute-force the plates apart. :-)

Brute-force clutch plate separation: First make sure you have enough oil in the engine (wet clutch), then basically you're looking at either riding it with the clutch lever pulled in until the plates come apart or with the rear wheel in the air CAREFULLY running it in first gear against the rear brake while the clutch is pulled in.