Question about 2003 kawasaki KX 250

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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

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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. www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx
i was riding along and the clutch just stoped - dd54330.jpg2cc50b7.jpg

Posted on Jun 17, 2009

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Go on line with the Honda Website and request a Honda 230 repair manual or go to a motorcycle shop and get it, or go on line and find a company that sells the repair manual.

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Hi, I have a 2006 zx10 and I had a bent clutch rod after changing a broken clutch lever, so after installing the new one and the clutch is hooked up when i start the bike and pull the clutch in dropping...


You may have a kick stand switch which will kill the bike if you try to ride off with it down, The switch on the clutch lever is so you cannot start the bike in gear unless its in neutral. There should also be a switch that goes in the transmission that works along with the other switch(es).
If at least one of these has a fault then that may be your issue.

Look at the clutch lever switch closely. Sometimes they have a small pin that the lever touches. If that small pin broke off then the lever cannot make contact.
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Thank you for contacting FixYa with your inquiry.
With new clutch frictions you will notice you have to pull the clutch lever a little further to disengage. This is normal but there are a couple of things you can do to help ease the pull.
  1. Go down to a Power Transmission Distributor or Industrial Bearing Supply House and purchase a can of graphite lubrication with the long metal dispensing tube. It's needle thin nozzle fits between the casing and the clutch wire and will allow you to lubricate your clutch cable and ease a lot of the pull tension. Give it a good coat frequently.
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  3. You might be able to lengthen the small clutch engagement lever which really helps a ton. We used to cut them and weld a 1/2 inch adder in the center which increased the leverage and the pull became a one finger operation. Might be some longer aftermarket levers. Wrist muscles and tendons get sore after a long day riding with a lot stops that require clutching. Normal riding/racing you seldom use the clutch other than to get started.
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You need to determine whether the squeaking is being made by the engine, the primary, the drive, or the frame. While riding, pull in the clutch, does the squeaking stop or change in any manner? Is the noise there when the engine is running but standing still? Pull the clutch lever in and release, does the squeak change or stop.

If I had to say what I think it is, I'd say it's probably the rear drive belt is not tracking correctly due to the alignment of the rear wheel. Look at the rear wheel adjusters. They should be exactly the same on either side of the swingarm. Also, the belt must be tight. If not, a loose belt will make a squeaking noise.

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How do I adjust my clutch cable on 1996 katana, I just changed it and now it wont engage into gear.


It should be set so that there is about 1/2" play at the lever end before it takes up the clutch mechanism. Make sure the lever isn't bent toward the grip which would restrict it's travel. If the lever is made of aluminum and bent, don't try to straighten it when cold--it will break. Heat the lever with a propane torch until fairly hot, then gently do the straightening. Shift the transmission into first gear, pull the clutch, and try to push the bike to test for release. Don't run the engine until it works as described. If this doesn't work, review the installation of the cable. Hope this helps!

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1 Answer

My bike wont go into gear it just kicks back out and cuts off engine. I can run it on centre stand but cant drive it,I have noticed that my clutch lever has lost its resistance can i just adjust this...


I'm not femiliar with your bike. But a bike is a bike when it comes to some problems, and yours is not disengaging the clutch. So, if its hydrolic than you need to bleed the air out of ituntil you lever feels solid but with just a littls free play. Same thing if it's a cable. Adjust it all the way tight , so that the clutch fully disengages then back it off until there is alittle free play in the lever. You need to be able to squeeze the clutch with the bike on the stand and have the rear wheel stop turning. Don't ride it any other way or you'll toast your gear box. Not cheap. Happy trails.

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2003 yz 125 clutch


This sounds like dirt and grit in the oil is causing the clutch to grab. Change the gearbox oil. Ride the bike for a couple of hours using the clutch often. Now drain the oil again and put in fresh oil. This will flush out the dirt and grit. Use 10w40 motor oil. Stick with the major brands; Pennzoil, Quaker State, Mobil or Shell. Do not use synthetics or oils with "special" additives.

Other possible causes are > a need to adjust the clutch lever for 1/4" free play at end of the lever > warped clutch plates or friction plates > Clutch has been worked on and assembled wrong > low oil level in the gearbox > frozen clutch hub bearing > Incorrect clutch cable being used.

Please post a comment after the double oil change. The 2x oil change is a cheap way to eliminate a possible cause and hey, it isn't gonna hurt anything. If you still have the problem I can help with a clutch rebuild.

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This sounds like the kick stand switch is bad or not making full contact.


Please take time to rate this a fixya

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Hi Jlrelect,
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