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I believe the arm is on top of the case on the left hand side attached to a shaft that goes into the case. It also may have a bolt in the side of the case below the arm that has a machined shoulder on it to retain the shaft from pulling out. If it does, remove it.If this is the way it's set up, it actuates the clutch thru a rod that goes all the way across the motor inside the hollow shaft that the clutch is mounted on. I don't have specific experience to the 250 KX, but I've been in the little ones and that's the way they're set up. So here's what you do-
Drain the gear oil and remove the round clutch cover on the right side of the bike. Remove the 5 or 6 washered bolts and the springs from the clutch pressure plate. Remove the pressure plate and you'll see the clutch lifter-it's a short rod with a flat bearing on it located in the middle of the clutch shaft. Remove it and using a small magnet tool go inside the hollow shaft and retrieve the actuating rod. There may be a ball bearing with it as well, although I don't think there is in that bike. Anyway, don't lose it if it has one and pay attention to which end of the shaft goes to the clutch arm. You can now replace the arm. When your putting it back together, rotate the arm with your fingers and make sure the lifter is moving up and down before you put the pressure plate and springs back in. Good luck!
i would say the clutch itself could be worn out ? maybe you need to replace the clutch? hope this helps... i would say either clutch basket or clutch plates....hope this helps
Using 5w oil with stock springs, your oil level should be about 100mm from the top
with the fork fully compressed, damper rod pushed all the way down, and
the spring out. I hope this helps and good luck. Please vote and leave a message.
Clutch plates are probably toasted. Drain the oil, remove the cover where the clutch cable goes into and check them out. Not hard to replace but you do need a special tool to get the plates off/on.
I would be more concerned with the stuck gear than the clutch, but we will start with the clutch.
The push cam may be bent or deformed and the push shaft may be bent. Assuming the ball bearing is in place, the cam and rod are all that can really go wrong. The rod slides out of the left center case. You will need to loosen the springs to get the left side cover back in place. Roll the rod on a flat surface to see if it is bent. I fear a bent shift fork is causing the gearbox to be stuck in third. Fix the clutch and then post a comment to get back to me.
I'm not 100% sure because I have'nt had much dealings with yamaha dirtbikes but I do know that on Hondas and Kawasakis there are no rod caps to remove the rod from the crank, the crankshaft actually splits and the rod slips off. They are a very tight press fit and have to be reassemled perfectly or it will throw the whole balance of the engine off. I recommend taking it to the dealer and letting them do it. I know that on my Honda CR 125 instead of trying to replace the lower rod bearing I was able to purchase a crankshaft with a new rod already attached. Hope this was helpful.
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