Clutch Lever stiffness...1996 Kx 250

[KawiSlinger19]

Hi guys!

     I've reassembled the clutch assembly according to factory specs. I have replaced the frayed clutch cable with a brand new one. I have also already applied new gasket material and secured the clutch cover =/ ... But it didn't fix my problem.

     The only thing left that I can think of is that the Clutch Actuating Arm is out of positions with the push rod? Is there a certain position that the Actuator arm has to be in before reassembling the push rod?

      Any ideas would be great! Thanks!
        KawiSlinger19

[KawiSlinger19]

Ok I've just disassembled and reassembled the push rod and actuating arm... all are operable and fine. My cable also has no bind and slides freely off the lever... so here's what I discovered:

     My lever and perch do not match up. In fact, my lever seems to have tweaked the perch and it is now stripped... I'm not sure if I just didn't notice it before or if one of my spills on the track gunked it up. Regardless, I am going to replace with a universal (due to budget) and I'll post a reply as to whether it worked or not.

[sandblaster]

Sounds like you have the problem well in hand.
Here is something else to consider.
Billet extended clutch arm.





You can get a YZF450 (Quad) clutch arm (About 20 or less on eBay) and a Billet arm for the YZF450 clutch arm on ebay for about 30.
Remove the clutch arm from your 500.
Cut the top off your KX250/500 clutch arm removing the lever part completely.
Then, cut the top of the YZF450 clutch arm off leaving about 1/4" of the shaft on it.
Weld the top of the YZF to the bottom of the KX250/500 clutch arm.
Install on your bike and enjoy about a 20% easier clutch pull with no hydraulic clutch.

[Hesher66]

I have no idea what to say to help with the clutch ,but if you want to make your bike look a little more newer u can cut down the number plates about 2 inches

[motorsickleman]

sometimes previous owners have a habit of putting heavier clutch springs in the clutch, my ebc dirt racer kit for my 88' cr250 came with heavier springs.  i put them in but it made it unbearable to ride, although at the time i hadn't performed any of the proper maintenance on my cable and lever pivot.  but still it made the clutch lever so tight that i went back to the factory springs.  this was like 10 yrs ago and i have since become a motorcycle tech and learned much since then.  you should try out the msr aof clutch perch assembly, it doesnt break the bank and it has a set of ball bearings in the lever pivot.  they use a late model honda cr lever so replacements are easy to come by.  i put them on 4 of my bikes, suzuki, honda and kawasaki so now they all have the same lever.