Question about 2003 kawasaki KX 250

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97 kx250 just replaced clutch hub, and basket. we can't put oil in yet beacuse we misplaced the plug, but when we got it all together and pulled the clutch in and pit it in gear it still grabbed.

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If you tried the clutch dry it will grab. if you tried it with the oil in it and it grabbed, then adjust the cable. about 3 mil gap on the lever.

Posted on Mar 19, 2010

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1 Answer

Putting a clutch together

hi there you need to take the clutch cover off after draining the oil ,remove the bolts going into the clutch basket take the springs out as well if you have the cash put in new springs when installing the clutch ,after you take the outer off then take out the plates and have acheck on size and wear ,then there should be a large nut and lock washer tap down the tab that stops the nut spinning loose then put your foot on the back brake and undo the nut this will be very tight if you have a air rattle gun this makes life a lot easier .then replacing the clutch basket it would be good sense to put a new bearing in the clutch houseing then put it back together in the oposite direction cheers hopes this helps cheers

Mar 27, 2014 | Husqvarna TE 610 Motorcycles

1 Answer

My clutch wont work

Please see this schematic to understand your clutch.
There are springs which press two SETS of many plates together. One set is metal disk construction and splines into the inner hub of the clutch basket assembly. The other set is made up of metal, with (often) compressed cork material - these spline into the outer hub. When the lever is pulled in, the spring pressure is relieved off the plates, and the inner and outer hub are independent of each other. When released, the springs push the plates together, locking the inner hub(engine power) to outer hub(transmission) Now that you understand how it works, I'd say the solution is clear, open up the clutch and take a look at your plates.

Dec 01, 2010 | 2002 KTM SX 125

1 Answer

How do i know i need a new clutch and clutch basket in my 2002 cr 125

Clutch friction plates are often the worn out component of that assembly. IF the plates don't spline in correctly with the basket due to some physical damage, then you should replace the basket. The clutch is comprised of an inner and outer hub that become interlocked through metal disks and friction disks pressed together under spring pressure.

Follow this link to a schematic of your 2002 honda cr125 to see how it all fits together.

Nov 28, 2010 | 2002 Honda CR 125 R

1 Answer

Clutch locked up on my 82 Suzuki dr250 I am at a loss what should I do.

your clutch is simply a stack of friction disks and metal plates. The friction disks are splined into the outer hub ring and alternate, one friction disk / one plate / one friction disk / one plate etc. It's very simple to free this up if it's locked up. remove clutch cover. If you are unsure which is your clutch cover, follow the clutch lever cable to the actuator arm. remove the cable from arm and all bolts holding the cover. as you pull out the cover, you will see the arm rotate that's because it's geared into an arm that is connected to the front plate of the clutch basket assembly. You'll see it as soon as you pull it off. now you'll be looking at a round plate with 6 bolts with springs underneath. when you arent pulling the lever, these springs are extended and push the friction disks and metal plates together, thereby locking the inner hub to the outer hub. The inner hub is connected to the crank, and the outer hub is connected to the transmission input gear. So, if pressed together by the springs, your engine running causes your bike to move. Pulling the clutch lever in pulls the spring tension off the plates and allows them to separate. This allows your engine to be disconnected from the transmission. If your plates are locked together you will remove them one by one if you can and lubricate between each plate and disk and reinstalling. Pay close attention to how it came apart. Reinstall bolts and springs reinstall cover, aligning the lever gear teeth with the front of the clutches teeth correctly. put it all together and see if you are okay now.

Nov 23, 2010 | 1988 Suzuki Rg 250

2 Answers

Cr 250 2002. Clutch will not disengage. All has been inspected and looks OK. It seems like the discs are not getting the proper spread between them to free up tranny. With all slack out of cable to get...

.25" is more than enough to release the clutch - if this is measured at the "hat" (pressure plate) of the clutch pack.

Most of these kinds of clutch problems are caused by two or three things: Incorrect oil, rusted plates or a notched clutch basket. There is nothing in the clutch pack to separate the clutch discs. The springs on the pressure plate push the stack together and pulling the lever relaxes this pressure, but nothing actually spreads them away from eachother.

If you use SAE motor oil for the transmission you will experience stiction - the suction caused by the oil is enough to keep the discs stuck to eachother pretty tightly. When cold, the stiction can be pretty strong.

If you take off in first then pull the clutch in and rev the engine, will it release then or will it pull just as hard as normal?

Have you blown your water pump seal? Water in the cases can rust the plates pretty quickly which can lock a clutch up tight. Something else to look for.

I suggest taking the discs out and examining your clutch basket and internal hub for notching if you do not feel the oil could be the culprit.


Dec 16, 2009 | 2005 Honda CR 250 R

1 Answer

KX250 Won't Disengage Properly

try to tighten down the clutch plates they can just be slipping

Aug 27, 2009 | 2003 kawasaki KX 125

2 Answers

Puting wrong oil in transmition

The problem did not start untill the 10w30 Honda transmission oil went in. It isn't the 10w30 thats the problem. It's the TRANSMISSION oil as opposed to MOTOR oil. There is a difference. As I said before, the swelling may or may not go away.

Best wishes Ryan :)

Apr 19, 2009 | 2003 Yamaha YZ 125

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