Question about kawasaki KX 250 Motorcycles

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I have a 91 Kx 250 dirt bike that the clutch is really giving me a fit on. I replaced the clutch plates, hub and basket. The basket is worn a little but was filed down by me. I run 10-40 non synthetic oil in it. I know it's been put back wright according to the parts diagram. The bike fires up on the first or second kick but when about to place the bike into 1st gear, it is grabby, loud (kinda like metal against metal. Like I said, under high rpms in first gear this bike is terrible and makes a pretty horififc sound. It does not do this in any other gear. My clutch cable is pretty worn but i havent found anything saying that it would act that bad by doing this. How would it be my clutch cable if it shifts fine in the other gears and i dont hear those sounds and feel it jerking? I've researched and researched till I'm blue in the face. At this time I'm torn. I will buy a new cable and release lever shaft with also checking the bearings on the clutch side. I'm really hoping that this is a clutch problem and NOT first gear stripping out.. Any info will be great. What would cause it to **** like that while riding and not do it in any other gears?

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Posted on Jan 02, 2017

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SOURCE: 91 kx 250 clutch too tight

hi m8,, wen u put spring bolts and springs on,, u must do them right up ,, untill the spring is completly comprest,, ,untill the spring bolt wont do up any more,,cheers

Posted on Jan 23, 2009

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SOURCE: 2008 Z750 bad grinding noise in first gear

It is possible that the first gear shift fork in the transmission is bent causing the 'dog-clutch' between two gears to just barely mesh. With engine off, push the shift into first and clutch lever released. Rock the bike back and forth to see if the gearing seems to be jumping in and out. There may be a problem with the shift lever shaft mechanism not allowing a complete shift into first gear. Hope this helps!

Posted on Apr 11, 2010

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SOURCE: Dirt Bike Shifting gears problem(1972 yamaha dt 250 2stroke)

it will be down to adjustment, there are 2 ways to adjust one close to the engine casing and one at the lever just have to get a good balance :)

Posted on Apr 11, 2010

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SOURCE: tri z I havnt


first thing. do not panic......
jumping and stalling after storage is almost normal. most of my bike will do the same, the oil and the pressure on the clutch does tend to stick the plates together slightly.
all i usually do is put the bike into a high gear (with the ignition OFF), pull the clutch in and rock the bike back and forth a few times. the engine may turn once or twice, but it will usually free off. there may still be a little bit of drag on the clutch for a few miles but this will usually clear up.
lack of power after storage is usally due to stale petrol. drain the pertol and replace with fresh.

if the bike was running ok when it was put into storage, then there is no real reason why it should not run fine now.

the problem you have now is quite simple, and i will admit that i have done exactly the same thing myself when changing clutches.

when you took the springs off the cover and removed the cover, you may have noticed that the outside of the "basket" it toothed, and the inside edge of the cluth cover has the same teeth.
when you put the cover back on, these teeth must line up and interlock for the cover to move freely. there is usually only 1 correct position for these teeth to line up, AND for the spring holes to line up as well. if there are 4 springs on the clutch, then the cover can appear to fit in 4 positions,but the teeth will not line up, and the cover will lock itself to the outer edge of the basket instead of sliding over it on the teeth.
if you look carefully, you can usually find an arrow, or a line on the cover, and a matching mark on the basket that will line up for the correct position.
if you cannot see a mark, then place the cover in each of the positions that the springs line up correctly, and on one of these positions the teeth will also mesh correctly and the cover will probably slide on another 5-6mm. this will be the correct position.

i have made this exact mistake a few times in the past and know how easy it is to do, and how frustrating it can be (and how worrying).

just reallign the cover, put fresh petrol in the tank, and after a few miles to blow out all the dust, you should be fine.

please feel free to ask for more advice if there are any more problems.

good luck
hope this helps

Posted on Jun 28, 2011

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Paul 'W'
Onyer~EDson(:0) {#><
Please remember to politely rate my effort!

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