Question about 2002 Honda Civic

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1991 KX 250 super tight clutch

1991 KX 250. As far as i can tell there is nothing broken inside. The cable is old and i took it off to see if that was it but it seems fine. the lever on the outside of the case that works the shaft to release the clutch is so tight i have to use a big pair of pliers and alot of muscle to move it without the cable on. I checked a parts diagrahm to see if i was missing a washer of something but everything in the diagrahm is in the bike. PLEASE HELP!!!!!

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Sounds like your clutch springs are old they tend to get hard as they get old. but even with the good springs you cant move the shaft with your hands . take the clutches and basket out its not hard just remember how it comes apart lol

Posted on Mar 04, 2009

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If it's cable actuated clutch, the cable may have snapped, which is also indicated by the clutch pedal dropping to the floor or becomes lighter to press. Check at the transmission bell housing, the clutch lever may have been broken or bent. If it uses hydraulic system, the slave pump may have been dislocated, at the transmission side.

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Driving 95 camry manual then clutch went super tight stiff could not change gears i suspect clutch broken?


The clutch is operated by a steel cable moving in a sheath when the clutch pedal is depressed and released. This operation is very similar to the hand brake of a bicycle.

If dirt enters the cable and becomes lodged between the sheath and cable, it will require more pressure to be applied on the clutch pedal to operate the clutch. The same thing can happen if water enters - it can cause rust to form on the cable and sheath with the same results. Because is requires more pressure to operate, the small individual steel strands the make up the cable may break - and the broken ends become jammed in the inside of the sheath. Because your leg muscles are some of the most powerful in the body, you can generally easily overcome the additional resistance offered by the rust / dirt. Only when the damage is done do you realize there's a problem.

It sounds like the clutch is not being allowed fully released - so it is slipping while driving. This is likely to be the source of the burning smell you are noticing. If you continue to drive the car without being fixed, you will need to have internal clutch parts replaced sooner that the normal replacement interval (the clutch is a normally replaced item similar to brakes).

The fix is replacing the cable itself (if it is a cable related problem). Your local mechanic can do this job fairly inexpensively. If it is the results of clutch parts in the transmission that have failed (pressure plate, throw out bearing, etc.) the repair costs can rise quickly.

I hope this helps and good luck!

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Sounds like a fan clutch problem or ??
Can you drive it and when it quits cooling check and see if the compressor is still running ?

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