Question about kawasaki KX 250 Motorcycles

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91 kx 250 tight clutch

In a 1991 kx 250 does anybody know if a ballbearing is suposted to go in between the clutch actuator and the rod. (a single BB) there is not one in mine but it seems like there should be to take the resistance away? It dosent show one in a parts diagraham on kawasakis web sight eighter but i cant figure out why else my clutch is so tight to squeze. Everything else seems fine but as soon as i put my springs and the bolts back in it gets wayyyyyy to tight to squeze the lever.

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  • Anonymous Jan 23, 2009

    Me too

  • Jessie Lamison Jan 24, 2009

    Im thinking it has the wrong springs installed. It has a real thick guage springs in there and i have and 82 kdx 250 that i took apart real quick to compare them. I know there totally different bikes but it is a 250 also and its springs had a way smaller gauge to them. Im just gonna get a set off ebay for $8.95 and give it a shot. thanks for all your help.



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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!

Posted on Jan 24, 2009


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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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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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