Question about kawasaki KX 250 Motorcycles

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Clutch wont disengage 250 kx 250

It wants to pull all time

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  • 23 Answers

Here's how I'd try to fix the clutch:
1.) Try to adjust the cable at the handlebar; usually there's a little bid of clutch lever travel (like 1/4"-1/2") before the clutch disengages. For right now, adjust the clutch so that there isn't any play and the adjustment all the way out. If the clutch disengages the transmission, then you know you have to fiddle with the cable to get it adjusted properly.
2.) The clutch plates could be sticking: here you'd have to take the clutch cover off and get to the clutch. Remove the clutch (usually an impact is ideal for removing the clutch holding nut. Take the clutch apart (steels and clutches), make sure they aren't sticking together. Then dip the clutches in oil, then reassemble.
3.) Sometimes the clutch basket (holds all of the clutches and steels in a "basket") gets grooves in it. These grooves prevent the clutch from disengaging. Sometimes you can file the clutch basket fingers down to remove the grooves. Alternatively, if the clutch basket fingers are really worn, you may have to replace the clutch basket.
Typically, when your in the clutch side of the engine case, I'd examine 2 and 3 (above) at the same time.

Posted on Mar 04, 2018

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6 Suggested Answers

6ya6ya
  • 2 Answers

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Posted on Jan 02, 2017

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onyeredson
  • 404 Answers

SOURCE: 1991 Kawasaki KX 250 super tight clutch

Hi!
Help is at Hand (Excuse pun),
This problem described strongly relates to a seizing clutch cable or frayed.
If you remove it try and pull/push the inner with your fingers there should be No resistance, you may get away with a good oiling but I would recommend replacement.
Good Luck!
Paul 'W'
Onyer~EDson(:0) {#><
Please remember to politely rate my effort!

Posted on Jan 21, 2009

goofduck
  • 490 Answers

SOURCE: 03 zx12r clutch wont disengage

the clutch disks are stuck together

Posted on Apr 21, 2009

co7196
  • 3433 Answers

SOURCE: Clutch wont disengage

Wet clutches need the proper oil. Is there any possibility it has the wrong oil?

Posted on Jun 19, 2009

  • 3567 Answers

SOURCE: recently snapped my clutch lever off my kx 250

Be sure you were given the correct cable, The stock cable is part number 54011. Compair the old cable to the new one.

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Posted on Aug 02, 2009

97F350diesel
  • 1326 Answers

SOURCE: clutch noise when disengaged

Sounds like your syncros are out of wack or a worn clutch. Check to see if they need adjusting call a shop for service). try making sure the fluid is at the proper level also

Posted on Aug 06, 2009

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1 Answer

1991 Kawasaki KX 125 clutch hard to disengage


Hi, Chris and the usual suspects are:
1. Clutch cable bent, kinked, pinched, rusted or needs lubrication.
2. Hydraulic clutch hose collapsed or pinched.
3. Improper clutch adjustment.
4. Clutch plates rusted.
5. Pressure plate or springs to heavy for service.
6. Damaged clutch shell.
7. Damaged, bent, or stuck push rod assembly.
8. Faulty worm gear mechanism.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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OEM Parts for Kawasaki
1991 Kawasaki KX125 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Feb 12, 2014 | kawasaki KX 125 Motorcycles

1 Answer

2003 Kawasaki KX 250 hard to pull in the clutch lever


Hi, Anonymous and the usual suspects are:
1. Clutch cable bent, kinked, pinched, rusted or needs lubrication.
2. Hydraulic clutch hose collapsed or pinched.
3. Improper clutch adjustment.
4. Clutch plates rusted.
5. Pressure plate or springs to heavy for service.
6. Damaged clutch shell.
7. Damaged, bent, or stuck push rod assembly.
8. Faulty worm gear mechanism.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
very hard clutch pull on 99 kx125
hard clutch pull on 99 kx 250
https://www.howtomotorcyclerepair.com/images/Kawasaki-KX-125-KX250-Service-Manual-2003-2004-2005-2006-2007-2008.pdf
OEM Parts for Kawasaki
2003 Kawasaki KX250 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Jan 12, 2014 | 2003 kawasaki KX 250

1 Answer

2003 Kawasaki KX 125 will not downshift.


Hi, Travis and the usual suspects are:
1. Improper clutch adjustment or not disengaging.
2. Bent shift shaft.
3. Shift fork bent or seized.
4. Gear seized on the shaft.
5. Gear positioning lever binding.
6. Shift return springs weak or broken.
7. Shift return spring pin loose
8. Shift mechanism arm spring is broken.
9. Shift mechanism arm is broken.
10. Shift drum is broken.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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03 08 Kawasaki KX 125 250 Service Manual pdf
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2003 Kawasaki KX125 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

May 02, 2012 | 2003 kawasaki KX 125

1 Answer

2003 Kawasaki KX 250 won't go into neutral


Hi, Anonymous and the usual suspects are:
1. Improper clutch adjustment or not disengaging.
2. Bent shift shaft.
3. Shift fork bent or seized.
4. Gear seized on the shaft.
5. Gear positioning lever binding.
6. Shift return springs weak or broken.
7. Shift return spring pin loose
8. Shift mechanism arm spring is broken.
9. Shift mechanism arm is broken.
10. Shift drum is broken.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Won go into neutral
03 kx 85 wont go into neutral
https://www.howtomotorcyclerepair.com/images/Kawasaki-KX-125-KX250-Service-Manual-2003-2004-2005-2006-2007-2008.pdf
OEM Parts for Kawasaki
2003 Kawasaki KX250 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Apr 22, 2012 | 2003 kawasaki KX 250

1 Answer

I put the bike in gear but when i pull the clutch lever in, it wont disengage and stays in gear??


if the clutch lever feels it has plenty of tension, it may just be the clutch plates stuck together from sitting.

Roll start it and ride around while holding in the clutch, vary the throttle, and they usually unstick. Give it an oil change when it warms up.

May 18, 2010 | 2004 Honda CRF 250 R

1 Answer

2005 kx 250 clutch problem... stalls when putting into gear


Two stroke motors with wet clutches are notorious for sticking when left for a period. Older oiler will leave a slight residue on ends of friction plates. If it is a regular thing after every stop, you will need to rinse clutch with a solvent. You don't need to dismantle if you are patient and carefull when applying solvent as it may discolour alloy cases and paintwork. Use a premium grade MOTORCYCLE GEAR OIL only and your problem will be solved if your clutch is A1 mechanically.

Apr 23, 2010 | 2005 kawasaki KX 250

4 Answers

HOW DO I SHIFT A 2003 KX 250


pull your clutch in on the left handlebar push the shifter lever down and let you clutch out slowly while giveing the bike a lil bit of gas. But if you don't know how to ride i wouldn't be jumping on a kx 250

Sep 20, 2009 | 2003 kawasaki KX 250

1 Answer

I can pull my clutch but it doesnt engage


Does it not engage (drive) or disengage (releaase)?

Jun 08, 2009 | 2005 kawasaki KX 250

3 Answers

I have 2003 kawasaki kx 125 when you put it in gear with clutch in it jumps forward and dies. where do i start with this?


make sure clutch ,is disengaging properly when you pull in clutch lever,adjust lever until you have about 1/8" freeplay.if still not disengaging, you need to drain gearbox oil, take clutch cover off & inspect clutch pack, you may have friction plates sticking together.

Feb 18, 2009 | 2003 kawasaki KX 125

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