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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2005 suzuki s50 was left for 6M w/o riding and now clutch is not working, will change gear hard from NUTRAL to 1 or 2 and die, changed fluid and bleeded and still not working

how long had it been since you changed the oil, have you tried the clutch leave did it move smooth if not, it sounds like the push rod might be stuck you can try rolling it off in 4th or 5th gear if you have a big hill near your place or a buddy you trust to pull it,
these girls are fickle and don't like being left with out some love! don't just let her sit she will get her feelings hurt and get in your wallet! if this don't work you will need to pull the clutch basket apart or have it done good luck, LLAP

Mar 03, 2015 | 2005 Suzuki Boulevard S50

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Hey guys i have a fzr 250 its a 3ln year 1994 i

If your clutch is automatic, then you need to ajust the freeplay.
On your clutch cover you have the small bolt with a screwdriver head, and a locknut.
You loosen the locknut, and then turn the adjuster bolt with a screwdriver clockwise until you feel it stop, now back it of 1/8th of a turn(counterclockwise).
While holding that adjuster bolt in position, tighten the locknut and your freeplay is adjusted.
You should notice a nice smooth shift while riding.

If your clutch is manual, then adjust your clutch cable length at the handlebar.
If the hand lever feels tight after you adjust the cable, thats because you have new clutches & springs. New ones are stiff at first.

If your clutch adjustment is fine from the start, then you have transmission problems and that would have to be inspected to be able to correctly diagnois which part is bad.

It could be just a broke shift arm.

Dec 07, 2010 | Yamaha FZR 250 R Motorcycles

1 Answer

Bought a used 88 cr250 and like and idiot i didnt ride it first to make sure the tranny shifted properly...well, it didnt. when i pull in on the clutch to drop the bike in gear with the motor running it...

sounds like you need a clutch. Yes the friction plates should move a bit when you pull your clutch lever in that is how the clutch works what oil are you running in you tranny and have you tried adjusting the clutch cable? When you had your clutch apart what did the friction plates look like was there much meat left on them?

Oct 03, 2009 | 2005 kawasaki KX 250

1 Answer

I was riding along and the clutch just stoped working,apon further review i noticed the clutch lever on the engine came up what do i have to do to get it back in place kx 250 2001

Remove the right crankcase cover. Loosen the four springs. Remove the left crankcase cover and push the clutch shaft inward about 1/4". Now re-insert the clutch arm and put the left cover back on. Next tighten the clutch springs, 22ft lbs, then put the right cover back on. All Fixed! Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock.

Jun 17, 2009 | 2003 kawasaki KX 250

1 Answer

Clutch wont engage after kickstarter shaft installation.

The clutch lever must have been pushed in when i tried to install the push rod the first time so the push rod didn't get pushed in all the way.


May 29, 2009 | 1996 Suzuki GSX-R 750 T

1 Answer

Broken shift shaft

  • Obviously a Kawasaki dealer can replace the broken shaft. I assume you want to replace it yourself. I do not recommend you replace it yourself but if you feel able then > > >
  • Drain the gearbox and pull the engine from the bike. Remove the left case cover.
  • Remove the right side case cover. Remove the clutch.
  • Disengage the shift shaft pawl from the shift drum pins and pin retainer. See if the bad shift shaft will slide out from the center casings. I say " IF " because the shaft may be bent and may not slide freely through the casings. DO NOT try to hammer the shaft through the casings. You will scar the bore at the least and crack or break the casing at the worst.
  • If the shaft will not slide out freely, then you will need to cut the shaft in half from the clutch side and remove it from the flywheel side. A Dremel tool will cut the shaft.
  • Now install the new shift shaft and check to be sure the gears all shift smoothly up an down, ( rotate the clutch shaft while shifting ). A bent shift fork is a PROBABILITY anytime a shift shaft is damaged as yours was.
  • If you can run through the gears okay then re-assemble the engine. Add fresh oil to the gearbox and go for a test ride down the street. If the bike does not shift smoothly then you missed a bent shift fork in the prior step and will need to tear the engine down, split the certer case and then replace the bent fork.
  • Please rate this solution as a " FixYa ". Thanks!

Mar 18, 2009 | 2003 kawasaki KX 125

1 Answer

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!

Jan 23, 2009 | kawasaki KX 250 Motorcycles

2 Answers

1991 Kawasaki KX 250 super tight clutch

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!

Jan 21, 2009 | kawasaki KX 250 Motorcycles

2 Answers

2003 KX125 Clutch Problem

the clutch springs may be weak check the specs you may just have to change them

Jan 15, 2009 | 2003 kawasaki KX 125

1 Answer


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,,,,

Nov 10, 2008 | 1988 Benelli 900 Sei

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