Maintenance & Technical > KX250 / KX125

98 KX 125...Help!

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klaus:
I just got a 98 KX125 for 400bucks, needs work, but I plan on bringing it back to life. The kid I got it from said it ran great, and one day he was riding it and the clutch went out on him and he took the clutch cover off and found out that one of the 'arms' that the clutch spring bolt goes into had busted off. When I got the bike I took the disks, the inner hub, and the 'basket' out. Before I took that out I could rotate the crankshaft, and it seems to have decent compression. The kick start lever was stuck before I took the clutch out, but you could still rotate the crankshaft. I moved the kick start lever after I had the clutch out and it freed up instantly. Now heres where I mighta messed up, I put the clutch basket and hub back on without the disks, I just wanted to see if it would fire up cause he said it ran good prior to the clutch breaking, I got it fired up and it ran for 2 or 3 seconds and died. Ok, so it run, but the next time I tried to move the kickstart down it "locked" up on me. I took the clutch back out, put the bigger part of the 'basket' back on, rotate it back an forth, but it always wants to "lock" when you turn it counterclockwise, the way its supposed to turn as it runs?? So I thought maybe the impeller is sticking, take off the cover, THERES NO IMPELLER!!! Just a piece of what looks like the back of the impeller, and the bolt that holds the impeller is busted off. Where do the passages go that move the coolant through the motor? IF the impeller came apart, where can the pieces go? Lol...I am familiar with wrenching on two stroke snowmobiles, but I HAVE NEVER been inside a dirtbike motor..I need advice on what the problem can be...do I gotta split the cases and investigate further? Also, when I would rotate the clutch by holding the basket, if I go counterclockwise it moves a short bit, then it seems like it binds up?? THANK YOU FOR ANY HELP!!!!

diesel:
Well I'm a newbie here, but I have worked on quite a few Honda TRX250R's, so I'll try to help out.  Problem is, my ramblings are going to be based on the inner workings of a 250R.

There definitely seems to be a problem related to the clutch...maybe several problems.  The kicker turns the clutch basket gear which turns the crank.  If the kicker moves freely without the clutch, and the crank turns easily without the clutch, looks like you've already identified the cause of the problems there.  In fact, it sounds like you've narrowed it down to just the basket as the culprit.  I'd grab a manual and check to make sure that all the clutch assembly needle bearings, bushings, spacers, and washers are properly installed.  If something is missing from the assembly, the basket could be getting in a bind.  How well do the gear teeth mesh between the kicker gear, basket gear, and crank gear?

I doubt that the impeller has been gone for very long, based on the fact that you still have compression.  I would expect the lack of coolant flow would cook your top-end quickly without an operational impeller.  If you still have the back of the impeller, then you're only missing the blades and the bolt, correct?  Those pieces would have followed the coolant flow, which would most likely deposit them in the water passages of the cylinder.

klaus:
deisel,
       hey thanks for the info! I know the first thing I need to get is a repair manual! But, I did print off some pics from a parts microfiche? or whatever their called. I have all the right washers, needle bearings, and that. I can't see behind the basket very well when its on, but I can see as I'm putting it on the crankshaft. I can see where the teeth are lining up, sometimes I have to depress the kickstart lever a lil' to get those gears to line up so I can slide the clutch on all the way. once its on, if I move the kickstart lever down it will move some and then get stuck again. I've looked at all the gears that I can see inside there behind the clutch and none of them look like their gouged, or chipped, theres no shavings anywhere. Theres a set of gears just to the right of where the clutch sits, it has a nut on the end next to it, and above it theres a gear with a spring next to it, i can turn that nut with a wrench and it turns smooth and then it wants to bind up.  Turn back the other way and its very easy again. Now, I may have messed something up, I hope not. But a few times when I was trying to see why its 'binding' I kept force on the wrench when it was binding, and it all the sudden will move very easy again. None of those gears look like theyre twisting to the side when it binds either. Yes, I think the back of the impeller is there. It is a black plastic looking piece, and the bolt that holds it on is broke off. I suppode I'm going to have to use an "ez-out" bit to get that broken bolt out of there. I also noticed when I had the cover off that the previous owner used too long of a bolt for the "drain plug" so theres a nice indentation in there in the case. I will try to post some pics here.

Coop:

--- Quote from: klaus on July 10, 2010, 03:37:36 AM ---Yes, I think the back of the impeller is there. It is a black plastic looking piece, and the bolt that holds it on is broke off. I suppode I'm going to have to use an "ez-out" bit to get that broken bolt out of there.

--- End quote ---

That bolt comes out from the back of the clutch cover. Pull that clutch over off and you will get it out easy peasy.

klaus:
Coop,
      Thanks! So I just go inside behind that gear and the boltheads there? Oh yeah, if the impeller had come apart and its in the coolant passages, how can i get them out? Take the cyclinder off and blow air through it? The coolant passages I mean?

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