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The 250 has not been out this year and the clutch has stuck. Tried rocking back and forth in gear and kicking over with the clutch in. No luck. I could bump start and ride with the clutch held in but a good chance it will stay stuck and give problems on stopping or not start and stall Any other tricks I have missed ?.

That's a pain. You might have to whip off the clutch cover and separate them with a screwdriver.

Colin

My 350 mk3 used to do this on a regular basis .........completely cured with a new set of clutch plates, however my way to get it free was simply to start the bike and just run it up to near working temperature (by blipping the throttle....no tickover stuff ) once the oil is hot and thin and the clutch gets a bit of heat in it good chance it can be broken free, worth a try before you start pulling it apart.
Cheers,
George

Aye Colin,

A set of 2mm steel plates has cured all my previous clutch problems/sticking/dragging etc.

Always free the clutch off before starting and I have now changed over from a monograde 40w oil to a multigrade 15w/50. That too helps, with the clutch and warming the engine through, as well as being cheaper than the monograde. Delivered to my door.

I like George's suggestion, but have never tried it. Good luck!

Good health, Bill

Prevention:
Can do this on singles, too.

Hello Bob,
On one 450 I had the friction material replaced with Kevlar.
No more sticking clutch, no more slipping clutch. Best $300 I’ve spent on a single clutch.
The other two is the usual process of breaking the sticking clutch before starting them.

It can help to wash the fibre plates in petrol and a brass wire brush.
Also lap the steel plates to remove any burs.
Then remove any burs on the clutch basket so the plates can slide easily.
But the best solution is to replace the friction material as above.

Graeme

Hi all, The little beast has not run for a few years (3 ?) but it started up on the 3rd kick on very old fuel (proper stuff ) , I have new neighbours so can't run it long enough to warm up . Clutch still stuck . Looks like a drain off and strip is needed . Dare not try to ride with a stuck clutch ,Too much traffic ,and at 76 far too old for falling off.

You probably won't need to drain the engine oil, because its level is below the clutch cover.
You can use a carpenter's claw hammer through the small oval opening, to help lever off the cover, with a soft-faced hammer too.
Have a new cover gasket to hand.
Unscrew the six clutch spring screws to access the pack of clutch plates.
Watch for small pushrod parts falling off as the outer pressure plate is removed.
Pry the clutch plates apart with a pointy thing or screwdriver.
Reassemble.

Hi Jordan, I rebuilt the beast from a non running mechanical mess many years ago and have not had it apart since. Reluctant to do so as I have a history of half finished bikes ! . I answer to the name of Half a job Bob . It also does not leak a drop , Hard to better that !. I'm a bit curious as to your oil level, mine is about 1/3rd the way up the clutch , I always fill to the top of the tower ,bike on stand ,level drops when off the stand. Certain I could run with less as the motor runs cool and does not burn any , perhaps would reduce clutch drag and sticky issue.

I have stripped my clutch without draining the oil. I put a little bit of wood under the left side of the stand to lean the bike to the right as I wasn’t sure where the oil level sat. Maybe not necessary.
Ian