Question about kawasaki KX 250 Motorcycles

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91 kx 250 clutch too tight

Took it all apart. the cable rides smoothe by itself, the shaft inside that pushes on the basket rides smooth, the basket is in good condition, clutches and plates r good,but when i put the springs and the spring bolts back in it all tightens up too much to squeze the clutch lever. Was wondering if the spring bolts should be tightened until they bottom out or should i just tighten them untill i can feel the restriction on the lever?

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  • Jessie Lamison Jan 23, 2009

    thanks for your help



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Hi m8,, wen u put spring bolts and springs on,, u must do them right up ,, untill the spring is completly comprest,, ,untill the spring bolt wont do up any more,,cheers

Posted on Jan 23, 2009


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91 kx 250 tight clutch

are you shure you have ALL the clutch plates?? the cable is well lubed? the pushrodbearing/adjuster may be in the middle of the clutch basket cover plate. OR you have the wrong springs installed!

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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!

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1 Answer

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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

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First I would check cable is free in its case and not fouled anywhere. Next check the actuating screw that converts pull to push motionis it greased nicely and smooth in operation? Is the clutch push rod straight? Are any ball brgs fitted on it? (some may not apply to sei). Now guess you should re check the basic adjustments of cable and actuator. (may be onc/case cover) Finally I would check the clutch spring free length agaunst specscheck the basket is tight on shaft, check the basket for wear grooves onthe tangs, if necc take a file to emm! must be smooth. Check no wear groovs or burs on centre hub where plates side. Are plates within wear specs? Not burnt / blued up?Have you the correct oil in engine? (too thick wil drag). You havnt put a friction modifier in it? Hope this helps although you prob tried it all!! good luck,,,,

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