Question about 2003 kawasaki KX 250

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Clutch not engaging cable feels very slack

Recently snapped clutch lever off my bike put new one on cable has 2 much play tried adjustin to no avail

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Ok, three different possibilities here. first, you replaced your broken lever with a lever that has the hole for the cable end a little closer to the perch, and you dont have enough range of adjustment to tighten up the cable. this is probably the least likely scenario, since you need a very signifigant change in the lever or perch assembly to throw your adjustment off that far.
second, your cable may have frayed or just broke. follow the clutch cable all the way to the engine, and keep an eye on the arm that it attatches to. it should move when you pull the lever. if theres no movement, then your cables broken or frayed.
if you can see that the cable is pulling on that arm, then your problem may be internal. also less likely though. but as a last resort, if you have the mechanical knowledge, then check behind the pressure plate for anything that may have broken in the assembly that pushes the pressure plate outwards. IM not too familiar with the kawasaki's design, but there may also be an adjustment screw and locknut right in the center of the pressure plate. tightening up just a little usually solves this isssue.

Posted on Aug 03, 2009


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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.

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Old clutch cable snapped, tried replacing with new one, no pressure on the cable?

The first thing that comes to mind is that the new clutch cable is not the correct length (too long). Did you compare the old one with the new one? When you pull in the clutch lever you should be able to see the clutch release lever at the transmission move. If the lever is not moving then the cable is too long or needs adjustment.

Apr 24, 2014 | 2003 Suzuki GZ 125 Marauder

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I was releasing my clutch and heard and FELT a "snap." It's a 1993 Geo Metro with a 3 cylinder engine and manual transmission. After the snap it felt like it wasn't quite "grabbing" when I released the...

Try a new cable, and make sure the funky suzuki weak pedal
is not cracked or the spline at top end is not stripped.
there are 2 parts here. not counting the shift lever that can fail.
1: the pedal actuator and cable.
2: the clutch actual.

if the clutch lever moves (at bell) 1 inch the (no play) then the clutch is bad.
see that simple test? the 1 inch?
you step on the pedal and the lever on the throw out moves 1inch.
that is all the curator does.

the cables is only good for like 100kmiles, (more if lubed)
and like to break in the center where you cant see, they fry there
and prevents you from setting up free play right.
see the problem here? if the cable is bad , you had tension on the
bell lever and the clutch slipped and burned up.
the cable is the cheapest part and the lowest labor.
why folks replace it last , is a wonder. but see that all the time.

do you understand the free play rules here. on all clutches.
(cable or lever type)
it must have free play, 1/2 inch at the pedal or 1/8" at bell lever.
if not the throwout burns up.
if not, (worse) the clutch slips.
if not the PP fingers overheat and the spring fails, (anneals)
free play.
and changes to tighter as you drive and clutch wears.
if you cant get the free play right ,its a big issue.
the #1 reason is bad CABLE. $25 and its out.

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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

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

How do I tighten the tension on my clutch lever? My clutch isn't pulling at the lite.

Check your owners manual under maintenance for a description of how to adjust clutch lever "free play".

There is an adjusting knurled nut or adjusting nut (looks like a small sprocket) at the clutch lever... turning it clockwise will decrease the tension.. you probably need to turn it anti clockwise..Toward you as you sit on the bike to increase the tension.. remember there is only so much adjustment available... before you will need a new clutch.. Tinkering with this adjustment a few times in the driveway should help.. up to a point.

If you can't take up the slack this way.. you will have to loosen the lock nut at/near(the one at the end furthest from the termination point) to the the clutch and adjust (the adjusting nut is the one closest to the termination at the clutch) it at that end of the cable.. turn this adjusting nut toward the engine to decrease free play or tighten.. or away from the motor/anti clockwise to provide more free play) then readjust the lever end.. you basically want to remove the slop from a wearing clutch and stretched cable.

Nice bike.. enjoy.. ride safe

Best of luck

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I dont know if my clutch is bad or if my clutch chord is bad in my 1983 suzuki GS 650 L

I am assuming that the engine races on up-shifts rather than getting a good, positive clutch hook-up, so checking the following items would be a good place to start. Since the GS650 uses a rack and pinion style release, it has no true clutch "adjustment" except for cable and linkage play. First check that there is adequate free-play in the lever and cable- does clutch tension pull the lever hard against the perch bracket or is there some free-play? If there is play, also check that the lever pivots freely in the perch, since corrosion can often cause the lever to bind. If this checks out, you will need to determine if the release cable is binding. You will need to spin the cable adjuster on the lever perch inward to add as much play as possible, then disconnect the cable at both ends. Removing the lever pivot bolt is often the easiest method. Once both ends are disconnected, you should be able to pull the cable back and forth in the sheathing quite easily. If not, I recommend lubrication first (Use a commercially available cable lubricating tool from Bike Bandit- they are inexpensive and last a lifetime) or replacement if it is binding/dragging. I make it a practice to lubricate new cables prior to installation as well, since you will find operation and longevity improved. Last but not least, check the actuator lever on the clutch cover to insure that it rotates freely in the cover. Reinstall the cable and adjust, making sure that there is play. If this doesn't cure your clutch slippage issue, it will be time to replace your clutch.

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Aug 06, 2009 | 2003 kawasaki KX 125

1 Answer

Recently snapped my clutch lever off my kx 250

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


Aug 02, 2009 | 2003 kawasaki KX 125

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