Question about 2003 kawasaki KX 125

1 Answer

Recently snapped my clutch lever off my kx 250

Put a new clutch lever on now clutch cable has 2 much play and wont engage tried adjusting to no avail

Posted by on

  • 1 more comment 
  • ma_jones3 Aug 02, 2009

    yesthanks for your solution tom bones the clutch cable never snapped only the clutch lever since fitting cant get cable to right tension to engage clutch

  • ma_jones3 Aug 02, 2009

    when i recived t6he lever i had problems getting it to fit ihad to grind both sides to get it to sit in correctly compared both levers only difference was a few ml either side on the bit where it sits in holder i think maybe when i snapped the clutch lever off i may have stretched the cable?

  • Anonymous Mar 26, 2014

    don't have no adjustment on cable ther is a pin that fell out on insidecover witch way does it go in

×

Ad

1 Answer

  • Level 3:

    An expert who has achieved level 3 by getting 1000 points

    Superstar:

    An expert that got 20 achievements.

    All-Star:

    An expert that got 10 achievements.

    MVP:

    An expert that got 5 achievements.

  • Master
  • 3,567 Answers

Be sure you were given the correct cable, The stock cable is part number 54011. Compair the old cable to the new one.

recently snapped my clutch lever off my kx 250 - d9b88da.png

Posted on Aug 02, 2009

  • tombones Aug 02, 2009

    So did they give you the correct lever? Match the new lever to the old. Are both cable adjusting points adjusted out to the max and you still have play in the lever? Just to clarify, when the lever is pulled in while in 1st gear, the clutch does not disengage; the bike wants to pull forward even with the clutch lever pulled in, correct?

  • tombones Aug 03, 2009

    A couple of milimeters out of position on the position of the end of the cable where it attaches to the hand lever can be a lot. I assume the mounting hole is closer to the adjuster than the original lever was? It is highly unlikely the cable has stretched.



    I want to clarify some information. Could you answer the following questions? Are both cable adjusting points adjusted out to the max and you still have play in the lever? When the lever is pulled in while in 1st gear, the clutch does not dis-engage; the bike wants to pull forward even with the clutch lever pulled in, correct? Does pulling in the lever dis-engage the clutch at all?

×

Ad

1 Suggested Answer

6ya6ya
  • 2 Answers

SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

Hi there,
Save hours of searching online or wasting money on unnecessary repairs by talking to a 6YA Expert who can help you resolve this issue over the phone in a minute or two.

Best thing about this new service is that you are never placed on hold and get to talk to real repairmen in the US.

Here's a link to this great service

Good luck!

Posted on Jan 02, 2017

Ad

Add Your Answer

Uploading: 0%

my-video-file.mp4

Complete. Click "Add" to insert your video. Add

×

Loading...
Loading...

Related Questions:

1 Answer

The clutch on my yz85 dirt bike is too tight when you put it into gear and let off the clutch it acts like it's still engaged what do I do?


well it should have about 3 mm of play at the clutch lever until it starts to pull the cable if it hasn't then adjust the cabke until it has,also a stiff sticking cable will cause this take the cable oyt of the clutch lever and out of the clutch arm in the clutch cover and try to move the inner cable with your fingers ,it shouk move very easily if it doesnt put a new one on it.

May 07, 2015 | Motorcycles

1 Answer

2003 Kawasaki KX 250 hard to pull in the clutch lever


Hi, Anonymous and the usual suspects are:
1. Clutch cable bent, kinked, pinched, rusted or needs lubrication.
2. Hydraulic clutch hose collapsed or pinched.
3. Improper clutch adjustment.
4. Clutch plates rusted.
5. Pressure plate or springs to heavy for service.
6. Damaged clutch shell.
7. Damaged, bent, or stuck push rod assembly.
8. Faulty worm gear mechanism.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
very hard clutch pull on 99 kx125
hard clutch pull on 99 kx 250
https://www.howtomotorcyclerepair.com/images/Kawasaki-KX-125-KX250-Service-Manual-2003-2004-2005-2006-2007-2008.pdf
OEM Parts for Kawasaki
2003 Kawasaki KX250 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Jan 12, 2014 | 2003 kawasaki KX 250

1 Answer

My clutch wont engage.


you need to take the clutch cover off and inside you will find a small shaft going up to your clutch lever. If that lever is broken you will have to replace that shaft.If the clutch shaft checks out check your cable that could be broken. If it is then replace and adjust and you are good to go. Good luck on the bike

Jun 16, 2013 | Harley Davidson XLH 1000 Sportster...

1 Answer

Clutch lever won't engage on 2005 honda rebel


Hi, Anonymous and the usual suspects are:
1. Clutch cable adjusted too tight.
2. Pressure plate center screw adjusted too tight
3. A broken clutch rod.
4. Slave cylinder piston stuck.
5. Clutch plate missing from the clutch pack.
6. Clutch plates have worn past minimum specifications.
7. Clutch plates crystallized due to incompatible oil.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
How to adjust motorcycle clutch cable
Clutch won engage can shift into gear
Honda rebel 250 Service Manual
https://www.partsfish.com/page/oem-parts-for-honda
http://mybikemanuals.com/honda

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e


Sep 07, 2012 | 2005 Honda CMX 250 Rebel

1 Answer

Clutch cable adjustment


On the back of the lever there is a screw and a round bolt. Unscrew that bolt until the right amount of play is in the lever you are problably going to want about 5-10mm of play in your lever. If it is to tight with no play it will start to engage your clutch ealry and possibly damage something. If you can put that screw the whole way out and you still have to much play you are going to want to replace the cable all together because it has streched and could possibly snap when riding. Good luck I hope i have answered you question A.J. Weaver

Apr 02, 2012 | Motorcycles

1 Answer

Zephyr 550 clutch adjustment


I looked up your bike and i belive that your bike has a cable clutch on it and not a hydrolic. So on your clutch lever there will be a bolt that goes into the the lever and a securing nut where the cable goes into the lever. If you unscrew your bolt the clutch get tighter and if you scew the bolt in the clutch gets looser. You should try to lubricate the cable and clutch. If it has been sitting for to long it may just be getting stuck. make sure that your clutch lever snaps back into possition. Your clutch lever has to have some play in it because if it is set really tight you will start to engage the clutch. If it is to loose then you wont be able to engage the clutch. You want about 6-10mm of play from the end of the handle bars to end of lever. So it will move that far before it will engage at all. This is a factory setting you may tighten or loosen depending on your riding style but remember the consiquences of what you are doing. if this is how your bike is set up then it is probalby your clutch plates. I hope this has helped you if you have any questions about any step just shoot me an email anytime. Good luck
A.J. Weaver

Mar 30, 2012 | 1991 kawasaki Zephyr 750

1 Answer

Clutch wont disengage 250 kx 250


Here's how I'd try to fix the clutch:
1.) Try to adjust the cable at the handlebar; usually there's a little bid of clutch lever travel (like 1/4"-1/2") before the clutch disengages. For right now, adjust the clutch so that there isn't any play and the adjustment all the way out. If the clutch disengages the transmission, then you know you have to fiddle with the cable to get it adjusted properly.
2.) The clutch plates could be sticking: here you'd have to take the clutch cover off and get to the clutch. Remove the clutch (usually an impact is ideal for removing the clutch holding nut. Take the clutch apart (steels and clutches), make sure they aren't sticking together. Then dip the clutches in oil, then reassemble.
3.) Sometimes the clutch basket (holds all of the clutches and steels in a "basket") gets grooves in it. These grooves prevent the clutch from disengaging. Sometimes you can file the clutch basket fingers down to remove the grooves. Alternatively, if the clutch basket fingers are really worn, you may have to replace the clutch basket.
Typically, when your in the clutch side of the engine case, I'd examine 2 and 3 (above) at the same time.

Feb 12, 2012 | kawasaki KX 250 Motorcycles

1 Answer

I just replaced my clutch cable, but now that I've put everything back together I have a problem. The bike will from neutral to first and back without the clutch lever pulled in. However it also...


Good news, you just need adjust the clutch cable..

Always order the part for your model and year when getting parts and make sure it matches in length with the old one. Note how much cable is sticking out of the housing.
Is it 3 1/2 inches or 4 inches or 2 inches. make sure the new one matches.

Put the new cable on with lots of slack.Slack at the adjuster, and slack at the handlebar adjuster
Now pull the lever in, it will be easy because of the slack.let it stay there.
It will stay against the grip.
As you tighten the cable adjustment down by the cover, you'll notice the clutch lever move out.
Once it reaches the top, stop adjusting and pull it in again.
Continue adjusting and pulling the lever until the lever springs back to the top.
You can feel resistence which is the clutches disengaging.
Make sure there is 1/8" free play when the lever springs back.
Now turn the clutch cable adjust on the handlebar outward, which will remove the rest of the slack.
Only leave 2mm slack on the lever.

Now start your bike up and it should work like new.
You want your clutch to disengage within the first 1/2" of pulling the lever in.
This ensures the clutches are definately disengaged by the time you get the lever pulled back to the grip when shifting.

If your clutches are slipping or dragging no matter how you adjust the cable then your clutches may need replaced.
But sounds to me like its just an adjustment.
Hope to be helpful
Big Al

Jul 25, 2011 | 1993 Yamaha FZR 600

1 Answer

83 1000 sporster clutch adjustment xlh


Loosen clutch cable adjuster locknut and the front of the outer primary cover and turn the cable adjuster inwards until a large amount of free play at the hand lever on the handlebar is recognized.

Remove the clutch adjuster access plug, Loosen the adjuster locknut and turn the screw inwards until it becomes harder to turn (starts to release the clutch) and continue turning 2 more turns to be sure clutch is disengaged.

Adjust all the free play out of the clutch cable by turning the cable adjuster in the front of the outer primary outwards. Do not put any tension on the cable, just adjust all the freeplay out of the cable and tighten locknut on the primary cover.

Now, Back off the adjuster screw at the release mechanism until the clutch is engaged and the screw turns freely. Then turn inwards until it just bumps and then back off 1/8 to 1/4 turn. Locknut the locknut down and install the access plug. There should be about a 1/16" free play at the hand lever.

good Luck
Steve

Aug 28, 2010 | 1979 Harley Davidson XLH 1000 Sportster

2 Answers

Engine cuts out when put into gear


Does it lurch forward a little? If so, First thing to check is the cable adjustment. As you pull on the clutch lever, you should be able to feel a little free play before the lever actually starts pulling the cable. You should have approximatley an 1/8 inch gap between the lever and the perch when lever engages the clutch.

If it's not the clutch dragging, check for a faulty kickstand switch.

Jun 10, 2010 | 1997 Yamaha Xv 250 Virago S

Not finding what you are looking for?
2003 kawasaki KX 125 Logo

429 people viewed this question

Ask a Question

Usually answered in minutes!

Top kawasaki Experts

Arnie Burke
Arnie Burke

Level 3 Expert

4995 Answers

yadayada
yadayada

Level 3 Expert

80637 Answers

bazzz7071
bazzz7071

Level 2 Expert

342 Answers

Are you a kawasaki Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides

Loading...