Question about 2003 kawasaki KX 125

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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

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  • 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



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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?



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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.
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