kx 250 clutch problems

[gonzo435]

Hi, ive been restoring a 2001 kx 250 that was a barn find . It  was in pieces but mostly there. It had the clutch bracket on the left engine case broken off. After some searching I found a left case off a 2000 model and ive reassembled the motor and im getting close to completion, the problem is when I squeeze the clutch lever the push rod moves the holder but doesn't make contact with the clutch plate. after double checking the parts breakdown im not missing anything but theres about an 1/8 inch gap between the release holder and the clutch plate. I noticed that the 2000 model parts breakdown shows a different style release holder with a bigger bearing where as the 01 has a different style , with a much different bearing on the end , im wondering if any one else has done this and had to use the older style release holder? Thanks for your time and I appreciate any comments.     

[toecutter]

So your right hand case is a 2001 and your left is a 2000? I believe the cases are machined as a pair from the factory and shouldn't be mixed and matched.

My 1999 had the cable bracket broken off to, there was enough material left to hold a bush I machined to keep the cable in place.

[TwiceDead]

Hey,

I would check if the clutch release lever and associated bearings are the same part numbers/dimensions for 2000 and 2001.  Clutch release rod as well.  I don't quite understand what you mean by release holder.  Can you show me on a fiche diagram?

[gonzo435]

What im calling the release holder is the part that slides on  the end of the  push rod, on the 01 it has a thin bearing and a washer and a thin spacer all held on with a circlip. The 2000 model has a much thicker bearing, a 6001 #  and it doesn't show a circlip holding the bearing on the holder . On rocky mountains site the push rod is the same number for 00, and 01 . After a lot of looking I put a flat washer on the end of the holder next to the pressure plate. That took up the slack and gave me a nice pull at the clutch lever. I plan on trying to find some 2000 model parts to see if that does the same thing correctly. Not sure if putting that washer in as a spacer would cause me any issues. Just trying to diagnose before spending unnecessary money. Thanks for responding.       

[TwiceDead]

No my 2000 doesn't have a circlip on the clutch release rod.  I would think that a year 2000 pressure plate and bearing may be the needed fix.