Clutch on my orion 250 dirt bike is rattleing and vibrating badly and the clutch seems to drag, how do i get the clutch basket off, do i need a puller?

Sounds like the clutch basket is worn you want to replace it really.

if you file the grooves, the plates will move about and likely break the basket, as the filing is not likely to be exactly even it will cause poor clutch opperation. sorry i dont know what years will fit but they dont change that sort of part each year, the bike breakers\wreckers may know that one.

.25" is more than enough to release the clutch - if this is measured at the "hat" (pressure plate) of the clutch pack.

Most of these kinds of clutch problems are caused by two or three things: Incorrect oil, rusted plates or a notched clutch basket. There is nothing in the clutch pack to separate the clutch discs. The springs on the pressure plate push the stack together and pulling the lever relaxes this pressure, but nothing actually spreads them away from eachother.

If you use SAE motor oil for the transmission you will experience stiction - the suction caused by the oil is enough to keep the discs stuck to eachother pretty tightly. When cold, the stiction can be pretty strong.

If you take off in first then pull the clutch in and rev the engine, will it release then or will it pull just as hard as normal?

Have you blown your water pump seal? Water in the cases can rust the plates pretty quickly which can lock a clutch up tight. Something else to look for.

I suggest taking the discs out and examining your clutch basket and internal hub for notching if you do not feel the oil could be the culprit.

Scott

Usually this is just something dry, grease the inner cable and grease the lever pivit, has also been the cltch pushrod for me before.

If you have 1/8" to 1/4" freeplay in the clutch lever the cable should not be the problem. You had best check the gearbox oil level.

What oil are you runing I like to run a Rotellat 15W-40

Its worth openning again the side cover and re-inspect that nut, not bad too if you can remove the clutch basket taking care of the plates as how they are fitted so that you don't get confused on assembling.
Check for the wear on the basket where the clutch plates go in and are thn driven especially those notches, check too the gear that mashes with the clutch system for any wear and not bad to check the springs too in the clutch basket.

Hope this helps .

hi,sounds like the clutch plates or the clutch basket .

dear sir the springs in your clutch is what puts pressure on clutch discs. these springs should all be the same length they should be measured with a caliper and compared to specs . the notchy feeling on your clutch is caused by wear spots on your clutch basket. if you are careful they can be filed down just keep them straight this will restore a smooth clutch feel. to check progress slip a clutch disk in the basket all outer dogs of the clutch plate must contact basket at the same time good luck jim