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Gear box help

This is a discussion on Gear box help within the 2-Stroke Motorcycles - Kawasaki forum, part of the 2-Stroke Motorcycle Forums category; Hello all, New to the forum! I recently purchased a 1986 KX250 winter project. The previous owner said it was ...

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Old 10-09-2009, 06:06 AM
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Join Date: Oct 2009
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looky here Gear box help

Hello all,
New to the forum!

I recently purchased a 1986 KX250 winter project. The previous owner said it was running 3 months ago. I changed the plugs cleaned the carbs and it still wouldn't start.

I decided to try a push start. Problem is the clutch would not disengage when in gear. I could pop it into neutral and move it around, but when in gear even with the clutch lever fully depressed it would not roll freely.

I adjusted the cable out all the way and still nothing.

I then decided to open the gear box. It was quite difficult to remove, the exhaust seemed to be in the way. However I was able to remove it.

Once removed, I took off the clutch cover and tried depressing the clutch to get a better idea how it works. I tried to take all the plates off to see how the cable connected to the back but I was stopped when I didn't have the correct size socket. Kawasaki website says 20mm, but my kit goes to 22mm and it was bigger than that?

I was following this youtube video which had a different kind of clutch adjuster. It was an allen key in the middle of the clutch so not helpful for my kx250.

Anyway the previous owner had put in a new clutch so it isn't worn.

I reassembled the gear box and found that my clutch cable was now limp. No tension what so ever. I also found that my kick start does not spring back great lol.

I'm new to this so pictures would be much appreciated.

Thanks everyone.
Aaron

Last edited by Clowey323; 10-09-2009 at 09:08 AM.
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