Author Topic: 2000 kx250 clutch issues  (Read 4070 times)

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Offline cthudson

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2000 kx250 clutch issues
« on: April 26, 2016, 03:40:44 PM »
When I got the bike the clutch was grabby and didn't want to disengage when you pulled the lever.  If you put it in gear the bike would inch forward and you had to give it gas to keep the engine from dying.  Replaced my clutch basket because it was notched pretty bad.  I also replaced the clutch plates, springs, and inner hub.  The symptoms got drastically better but were no where near perfect (compared to other bikes I've rode).  I then measured the movement of the pressure plate when I pulled the clutch lever and it was in spec.  So I am lead to believe the plates are getting enough clearance to disengage.

I rode it like this for a couple months and eventually got frustrated with not being able to idle in gear with the clutch lever engaged.  I replaced the clutch cable hoping this would fix my problem, it didn't.

The strangest thing is that with the bike in neutral (gear position) and you grab the clutch lever the engine rpm changes slightly.  Its enough to hear a noticeable difference in the exhaust.  It sounds like a slight load is being put on the engine. 

I need advice on what to check next..... any suggestions?




Offline sandblaster

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Re: 2000 kx250 clutch issues
« Reply #1 on: April 26, 2016, 03:57:56 PM »
What oil are you using?
The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline Foxx4Beaver

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Re: 2000 kx250 clutch issues
« Reply #2 on: April 26, 2016, 09:02:29 PM »
OEM or aftermarket plates?....
I'm not trashing aftermarket brands, as some are really good....but I've seen/had some aftermarket steel plates do this back in the 90's. Swapped back to OEM and it was fine. I was to believe there was a slight difference in plate thickness (metal and fiber) with the aftermarket that caused it.
Since I've been running OEM's, I've never had another issue...I run aluminum plates.
Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ

Offline Foxx4Beaver

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Re: 2000 kx250 clutch issues
« Reply #3 on: April 27, 2016, 07:17:31 AM »
welcome to the site BTW!
Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ

Offline cthudson

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Re: 2000 kx250 clutch issues
« Reply #4 on: April 27, 2016, 11:16:50 AM »
I use belray gear saver 80w.  I was recommended this oil by the local dirtbike shop.  The clutch plates are Tusk brand. The basket and inner hub are proX brand.  I took it all apart and did not see any signs of abnormal wear.

Offline Foxx4Beaver

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Re: 2000 kx250 clutch issues
« Reply #5 on: April 27, 2016, 11:37:01 AM »
the push rod and actuator looked ok too?
Excuse me, ma'am...but you've got extremely nice legs!!!...what time do they open???                                                                                                               https://www.youtube.com/watch?v=n8tCgN3aryQ

Offline cthudson

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Re: 2000 kx250 clutch issues
« Reply #6 on: May 03, 2016, 03:57:34 PM »
I'll test out some other oils.  With the bike off I've got and the clutch lever engaged I still have enough drag to feel the cylinder compress.

I have not been able to find any specs on the push rod and actuator.  I do not see any abnormal signs of wear and the push is straight.  What is the clearance between the pressure plate and the friction/steel plates supposed to be when the lever is pulled in?  I have 1.45mm of clearance.