1991 KX 250 super tight clutch

NO PROBLEM told just wild goose HUNT (chase)
IS MPH GAUGE NEEDLE STUCK? OR JUMPS LIKE MAD.? NO SYMPTOMS TOLD AT ALL.
1991 is long in tooth car. (no county told)
NO ENGINE told ,25 engines world wide.
and super hard to find manuals on it as it was paper manuals only then (not digital)
on most old cars like that with just 1 transmission A/T the VSS (is speedo dead and transmisson VSS errors)
the VSS1 is on the tail shaft on newer cars not this car..
this car is FWd making parts hard to find and hard work to fix. (some jobs are super hard)

VSS is the road speed sensor for MPH or KMH cluster.

old cars with old old hyrdamatic (BINGO), does not ever need any VSS to shift to higher gears.ever.

FACTS, BASED ON PARTS SEEN REAL. 1991
THE CLUSTER IS MPH GAUGE CABLE DRIVE
SO THE VSS IS INSIDE THE CLUSTER
END STORY.
NOW IF YOU SAID TRANSMISSION FAILS?
I TELL YOU HOW IT DID.
TV CABLE BAD. (Throttle to box)
VAC, MODULATOR BAD on box or hose bad to it.
TRANS, GOVERNOR BAD.
LOW PUMP PRESSURE IN IT ,VAST CAUSES ASK.
(AND HUGE LIST OF CAUSES AND TESTS)

why not post a problem first?
speedo dead
or
transmission fails. even both
so the helper knows what's up, even tell what works and does work correctly, in brief
? GOOD LUCK!

You must go through the fire wall like I said in your other post there's a grommet on it that sets in the fire wall go from the passenger compartment first and feed it through

If it's cable actuated clutch, the cable may have snapped, which is also indicated by the clutch pedal dropping to the floor or becomes lighter to press. Check at the transmission bell housing, the clutch lever may have been broken or bent. If it uses hydraulic system, the slave pump may have been dislocated, at the transmission side.

The clutch is operated by a steel cable moving in a sheath when the clutch pedal is depressed and released. This operation is very similar to the hand brake of a bicycle.

If dirt enters the cable and becomes lodged between the sheath and cable, it will require more pressure to be applied on the clutch pedal to operate the clutch. The same thing can happen if water enters - it can cause rust to form on the cable and sheath with the same results. Because is requires more pressure to operate, the small individual steel strands the make up the cable may break - and the broken ends become jammed in the inside of the sheath. Because your leg muscles are some of the most powerful in the body, you can generally easily overcome the additional resistance offered by the rust / dirt. Only when the damage is done do you realize there's a problem.

It sounds like the clutch is not being allowed fully released - so it is slipping while driving. This is likely to be the source of the burning smell you are noticing. If you continue to drive the car without being fixed, you will need to have internal clutch parts replaced sooner that the normal replacement interval (the clutch is a normally replaced item similar to brakes).

The fix is replacing the cable itself (if it is a cable related problem). Your local mechanic can do this job fairly inexpensively. If it is the results of clutch parts in the transmission that have failed (pressure plate, throw out bearing, etc.) the repair costs can rise quickly.

I hope this helps and good luck!

Sounds like either the air gap between the a/c clutch and the pulley is to far..Or the clutch itself is bad..You can remove the bolt in the middle of the clutch,,Work the face of the clutch off,,and take out the washer..If there is 2 washers then remove one of them,,and reinstall..If there is only one ,,try it with no washer...The washer adjusts the air gap

This is a common problem, and yes it must be welded (which is the only way). I have done this repair on many Toyota trucks years 1989-1995, all same issues. I welded the cracks on the upper pedal support plate on these trucks. Make sure the interior is protected and that there is nothing flammable around the driver side deck. Hopefully this help'd

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This sounds like a simple shift cable adjustment Your in 2 wheel but its telling you your in 4 wheel low all the time If this is correct the problem is at the shift lever inside the truck or at the transfure case its an adjustment of the cable

check wiring at a/c condensor and the a/c clutch fuse/relay

You may need to have the cable adjusted to allow the pressure plate to disengage from the clutch plate