Clutch wont engage after kickstarter shaft installation.
Well i recently replaced a kick starter shaft in my 2001 Kx 250. everything went smooth, or so we thought. when we finished the installation the clutch would not engage. were thinking that we didn't install the push rod correctly. the push rod goes right behind the pressure plate right? Does the lower clutch lever have to be clocked?
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Just remove the right side cover to expose the kick start mechanism. Remove the bolt on the end of the shaft, tow washers and guide then the spring. It has been awhile since I worked on the KX 250, but as I recall, the clutch does not need to be removed in the process of replacing the spring. I could be wrong on that. Below is the kick mechanism on your bike. Please rate my answer. Thanks.
Common cause of kickstarter not engaging(I am guesing that this is your problem) is a broken spring on the kickstart mechanism,or that the kickstart idler gear cerclip has fallen off(this allows the idler gear to move forward on the shaft & thus won't allow the kickstart gear to transfer drive to the clutch hub).Remove clutch cover, put kickstart lever back on shaft spline,activate kickstart lever by hand(easier with sparkplug removed+in neautral)as kickstart lever moves down 90 degrees the gear on the kickstarter mechanism should move out to engage with gear next to it(kickstart idler gear).If the gear on the kickstarter mechanism dosn't move outward it has a broken spring on the kickstart mechanism.replace spring and all should work.(if the spring is broken you need to try find the broken piece with a magnetic pick-up tool as the broken part can cause further damage if not removed)To do this job I highly recommend you first purchase a workshop manual which will guide you through these processes.After all a manual is the most valuable tool in your tool kit.
The kick shaft gear, idler gear, and clutch drum gear on the 1985 xr250 and below are smaller tooth gears than 1986 and newer. I have an 85 and an 88. I had to replace the 85 kick gears 3 times. The last time I replaced them I found that the larger gears on the 88 fit as long as you replace only the gears. The kick gear comes off the shaft and the larger tooth gear fits on the shaft. The larger idler gear fits where the smaller tooth idler was and the drum gear comes out and the larger tooth gear will fit there. Or the drum you have with the larger gear will now fit the other gears. This is a better solution than finding another drum with the smaller tooth gear because the smaller tooth gears will not last. I hope this helps.