Question about 2003 kawasaki KX 125

1 Answer

How do I install the clutch release shaft on a KX 125?

I have a 2003 KX 125 and I was replacing the clutch cable when the clutch release shaft came out slightly and would not go back in place. I am wondering what I have to do in this case. Is this problem easy to fix? When this happened, I tried rotating the shaft to see if it would go back in place but no luck. I was reading in the service manual that if the shaft is removed, then the clutch has to also be removed and the clutch release oil seal must be replaced. I have removed the clutch cover and pressure plates already. I have a new oil seal, but the shaft will not fit into the crank case properly even with the clutch removed. Any help would be much appreciated. Thanks!

Posted by rwpilgrim on

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The clutch arm where the cable connects is on the left and it connects to the clutch via a shaft that pushes a rod which then pushes a ball bearing sitting in the holder and then the holder pushes the clutch operating plate to dis-engage the clutch. The only seal is on the clutch arm shaft that goes into the casing. At worst, only the springs on the operating plate would need to be removed then a 1/4" inward push on the rod from the right side would give clearance for the shaft to be inserted.
.
Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock. www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx

A “very helpful” rating for this answer? Thanks!

Posted on Jun 11, 2009

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1 Answer

How do you replace a clutch in a 1998-99 Geo metro


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my wild guess. on what is there, M/T stick shift car.

M/T stick
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:
    • Negative battery cable
    • Transmission assembly and matchmark the flywheel to the engine
    • Clutch pressure plate cover by slowly and evenly loosening the bolts until the spring tension is released
    • Clutch disc

Trans out,
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the transmission fluid.
  3. Remove or disconnect the following:
    • Negative battery cable
    • Both front wheels
    • Backup lamp switch electrical connector
    • Clutch release lever from the clutch release shaft
    • Clutch cable bracket and move it aside
    • Negative battery cable and hanger from the transmission
    • Gearshift guide case bolts and set the engine wire harness and bracket aside
    • Speedometer cable
    • Starter motor
    • Two right side upper case-to-engine bolts
  4. Install an engine support fixture.
    • Both drive axles after properly supporting the transmission
    • Flywheel cover
    • Control joint shaft through bolt and separate the control shaft from the control joint
    • Gearshift control lever guide plate and separate the extension rod from the lever guide plate
  5. Support the transmission.
    • Bolts from the rear transmission mount
    • Left side mounting bracket bolts
    • Right side case-to-engine mounting bolts
    • Transmission through the left side of the engine compartment and make certain that the input shaft clears the clutch pressure plate

Feb 14, 2015 | Geo Cars & Trucks

Tip

2004 Hyundai Tiburon Clutch.


First you need to remove the Transaxle.

Manual Transaxle System REMOVAL

1. Remove the engine cover.
2. Remove the battery terminal.
3. Remove the air duct.
4. Remove the battery tray.
5. Remove the air cleaner.
(1) Upper
(2) Lower
6. Remove the back-up lamp switch.
7. After removing the CKP sensor, O2 sensor and oil pressure switch wiring bracket, separate the connectors.
8. Remove the brake fluid leveling sensor connector.
9. Remove the speedometer driven gear connector.
10. Remove the clutch release cylinder mounting bolt.
11. Remove the cotter pin of the shift cable (transaxle side).
12. Remove the cotter pin of the select cable. (transaxle side)
13. Remove the clip of the shift cable (transaxle side).
14. Remove the clip of the select cable (transaxle side).
15. Separate the steering column shaft joint.
16. Separate the power steering oil pump hose.
Be careful not to leak after separating.
17. Separate the hose after removing the clip of the power steering return hose.
18. Remove the upper connecting transaxle bolt.
19. Separate the start motor.
20. Install the engine support fixture.
21. After removing the tire, remove the caliper.
22. Remove the transaxle side cover.
23. Remove the transaxle side under cover.
24. Separate the tie rod end.
25. Remove the wheel speed sensor and the knuckle mounting bolt.
26. Drain the oil.
27. Remove the transaxle mounting bracket.
(1) Insulator bolt
(2) Body side mounting bolt (Upper)
(3) Body side mounting bolt (Side)
(4) Transaxle side mounting bolt.
28. Remove the front roll stopper.
(1) Insulator bolt
(2) Stopper bolt (Upper)
(3) Stopper bolt (Lower)
29. Remove the rear roll stopper.
(1) Insulator bolt
(2) Stopper bolt
30. Remove the drive shaft.
31. Remove the front muffler.
32. Remove the sub frame mounting bolt.
33. Install the transaxle jack.
34. Remove the transaxle lower mounting bolt to the engine.
35. Remove the transaxle assembly.

INSTALLATION
Installation is the reverse of the removal.

Then inspect and replace the clutch place and pressure plate.

INSTALLATION
1. Apply multipurpose grease to the release bearing contact surfaces and the release cylinder contact surface of the clutch release fork assembly.
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage and judder.
2. Apply multipurpose grease into the groove of the release bearing.
3. Apply multipurpose grease to the clutch release lever fulcrum contact surface of the clutch release fork assembly.
4. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and make certain that all oil or grease has been removed.
5. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.
Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.
6. Using the special tool, install the clutch disc to the flywheel. When installing the clutch disc, be sure that the surface having the manufactures stamp is towards the pressure plate side.
7. Install the the clutch cover assembly onto the flywheel and install the six (6) bolts through the clutch cover into the flywheel.
8. Tighten the bolts by one or two turns at a time, in succession, to avoid bending the cover flange.
If a special tool is not available, tighten the bolt temporarily and then torque to specification in diagonal torquing sequence indicated below.
TIGHTENING TORQUE
Single mass flywheel:
15~22 N·m (150~220 kg·cm, 11~16 lb·ft)
Dual mass flywheel:
20~27 N·m (200~270 kg·cm, 14~19 lb·ft)
9. Remove the special tool.
10. Install the transaxle. (Refer to GROUP - Manual Transaxle Assembly)
11. Adjust the clutch pedal free-play. (See CH-6)
INSPECTION
1. Check the diaphragm spring end for wear and uneven height.
Replace if wear is evident or height difference exceeds the limit.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
CLUTCH DISC
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease, and replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc if it is out of specification
3. Check for torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.
CLUTCH RELEASE BEARING
The release bearing is packed with grease. Do not use cleaning solvent or oil.
1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
INSTALLATION
Installation is the reverse of the removal.
Then remove pressure plate and Clutch plate.

1. Insert the special tool (that came with your clutch kit) in the clutch disc to prevent the disc from falling.
2. Loosen the bolts that attach the clutch cover to the flywheel in a star pattern.
3. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

on Jan 13, 2010 | Hyundai Tiburon Cars & Trucks

1 Answer

2010 Kawasaki KX 85 clutch will not engage


Hi, Robert and the usual suspects are:
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6. Clutch plates have worn past minimum specifications.
7. Clutch plates crystallized due to incompatible oil.
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9. Rear drive belt or chain broke.
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.
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https://advrider.com/index.php?threads/clutch-problem-kawasaki-kx85.1017465
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Jul 03, 2013 | 2010 kawasaki KX 85

1 Answer

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Jun 06, 2013 | 2003 kawasaki KX 125

1 Answer

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1 Answer

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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-
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Hi, Firefight685 for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
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Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e


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1 Answer

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I am not familiar with a 00 kx 125.

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I hope this helps.

Thanks for your interest in FixYa.com

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1 Answer

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Oct 29, 2010 | 2003 kawasaki KX 125

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