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Trying to help neighborhood kid who just bought a ragged out YZ250. The seller said it is a 1998...according to numbers on engine, it is a 1994. Regardless, here is the problem: The clutch lever has almost no travel and therefore does not disengage. The cable is adjusted as far as possible on the handlebar (and even a spacer was added to try to give it more travel). The root of the problem is that the clutch actuator arm is rotated about 30 degrees too much. (counterclockwise from above) I took the clutch apart, put in new friction plates and metal disk. The pushrod 1 appears normal and the pushrod 2 is the type with a ball bearing and no needle bearing. All of the parts are in place according to the exploded diagram...yet is as if the pushrod needs to be longer-yet it is not adjustable. If the pushrod was longer or you could put shim between the pushrod and the pressure plate, it would fix it, but this can't be the proper way. I hope I'm making sense...any advice is appreciated.
 
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