Maintenance & Technical > KX250 / KX125

Kx250 1994 clutch issue 😡😡

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Murch1995:
Hello guys I’m new to this forum, I’m in need of some help regarding my kx250 1994 clutch, I bought the bike and I had a quick ride around and I noticed it would creep in gear and was showing the symptoms of clutch wear so I replaced the clutch plates (which wear worn out )  and new gear oil etc, In the process of clutch replacement I checked the basket which was okay no grooves if I looked closely there was a very slight groove shown but not even enough for the plates to be stuck it was just showing signs of contact. So with the clutch plates replaced and basket okay I checked the push rod and all seems okay bearing is okay no play or wear. I then attempted to adjust the clutch once all back together and at the perch it seemed to run out of adjustment for example seemed like the cable was to short however I then noticed the cable was old and beginning to fray. So I replaced the cable for a new one correct for the bike but still can’t adjust the clutch. I attempted to test the clutch as it stands  so started it up and instantly stalled when I went to select 1st gear. Firstly does anyone know the solution?, secondly will a racing clutch lever and perch rectify the issue for example pro circuit or works or any suggestions of manufacture ? , thirdly is a new cable meant to be easy to pull in as it’s effortless?? , finally where does the clutch actuator arm need to be positioned?? Many apologise for the long essay but I just want the problem solved! Cheers guys!!

KXDINO:
Sounds like you might have put a part in wrong , only reason i say this as a example a 99-00 kx125 have alignment marks on clutch hub and pressure plate ,there for a reason, so check that out , i know someone who did the same with a 19 yz250f , if not sure get a work shop manual.

Murch1995:
KXDINO, I’ve inspected  and I can’t see any alignment marks??  A image would help if you could access one many thanks and would the clutch still operate correctly with standard perch I was thinking of replacing it fir a pro circuit or something similar.

KXDINO:
With the clutch cover off , does the clutch plates move when you pull the lever in ?

Murch1995:
Hello kxdino I’ve had the clutch cover off but not had the cable in the perch but would of thought pilling the cable is the same as pulling the leaver in however I have pulled the cable and watched the travel of the clutch pack and it moves about 1 to 2 mm and it’s got new plates fitted so can’t emagine the movement being to much seems okay at present put just seems to be when I adjust the cable at the perch I have no clutch and the actuator arm is pulled forward slightly rather than being straight it’s got to be a a very very small fault as all seems okay when cable pulled but I’m unsure 1to 2 mmm is enough to fully release the clutch ,my  oil is new also and plates don’t apppear to be sticking, real weird one but any other ideas? Thanks

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