2003 KX125 Clutch wont adjust enough

[Duty Bootie]

Hi All.....Back into dirt bikes after a long layoff.....Bought my son a KX125 - 2003 model......Working through some issues and wonder if anyone can help pls.

Can not adjust clutch enough to stop wheel turning while in gear with clutch fully in.  When you put into 1st at a stand still it grabs terribly and trying to kick start in 1st is nigh impossible with clutch pulled in.

I stripped the clutch plates out tonight to inspect for wear.  Seem to be OK.  Basket is fine and no grooves to be seen. 

However there seems to be quite a bit of play from the actuator where the clutch cable attaches and the push rod it pushes to release the clutch.  On the clutch side the ball bearing is in the piece that sits in the clutch cover (where the 5 bolts and springs are).  There is the washer and the flat bearing on that piece too, all seem to be OK.

I'm trying to figure out how to take up that bit of slack in the actuator.  Seems if I shim on the ball bearing part with an extra washer my issues will be over.

Or it could be worn clutch plates/friction pads, or worn actuator and push rod or all of it.

Any ideas or help would be very grateful.

Thanks, RH, Vancouver Island.

[motorman455]

Have you tried adjusting the cable adjuster near the upper end of the cable? Not the one at the lever but the one in the cable itself.

[Duty Bootie]

Yes I have.....Even with the cable removed and the cover on the side manually holding the actuator up with pliers still will not disengage the drive.

[KXDINO]

get the exploded view on all of this and check everything there , has it got the correct push rod for that model,  is it missing a part , who knows what the guy did who owned it before you .

[Easterncaperider]

I am having the exact same issue on a 2007 KX250. Clutch push rod seems to move at least 4mm, before making contact with the clutch pressure plate. at the end of the push rod, is a sleeve with a flat roller bearing and a washer. Downloaded an exploded diagram of the clutch and all parts seem to be there. Almost seems as if there should be an extra washer on the end of the push rod, or a metal ball somewhere, to take up the 4mm space??
Please help