Maintenance & Technical > KX250 / KX125

2005 KX250 Clutch Problem

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zwazuski:

--- Quote from: Friar-Tuck on April 12, 2010, 11:07:28 AM --- So If I understand you correctly, You can pull the pushrod out of the clutch side, and the release arm won't slide in the case any further?
  Something has to keep that buggar from falling out.  That is mounted horizontally right?
Oh well... Maybe the bump will lure in another 250 owner...
  Tuck\o/

--- End quote ---

Correct. I bent the arm over just a bit and it seems to clear the FWW now but it just doesn't seem right.

Friar-Tuck:
  Jinkies...
I'm in the process of getting a PDF  :wink:  hopefully with your bike.  I looked through numerous pages for free ones and came up empty handed...
  Maybe some of the other guys will see this and give it a shot.... :oops:
   Tuck\o/
     

Friar-Tuck:
 Z,
 I got a service manual for 125 & 250's but it doesn't show the same clutch arm arrangment...
  The KX125 shows the clutch release arm under the cover and horizontal.
 The 250 has the clutch arm outside the cover vertically like the 500's.
   However,  if I go to this service honda parts fische it looks like your pic.
 I can't copy and post the pic :| (like yours :oops:)

   Do you think one of the two caged needle bearings in the case could have gotten buggerd or twisted /not seated squarely? 
The only thing between the release arm and the push rod is the seal and the two caged needle bearings.

http://partsfinder.onlinemicrofiche.com/servicehonda/Kawasaki_OEM/KawasakiDB.asp?Type=13&A=76&B=6
   (go to the crankcase tab)
 See parts 92049c  Seal
 and  92046A  x's 2  bearings
  Tuck\o/

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