Question about 2003 kawasaki KX 125

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How do I install the clutch release shaft on a KX 125?

I have a 2003 KX 125 and I was replacing the clutch cable when the clutch release shaft came out slightly and would not go back in place. I am wondering what I have to do in this case. Is this problem easy to fix? When this happened, I tried rotating the shaft to see if it would go back in place but no luck. I was reading in the service manual that if the shaft is removed, then the clutch has to also be removed and the clutch release oil seal must be replaced. I have removed the clutch cover and pressure plates already. I have a new oil seal, but the shaft will not fit into the crank case properly even with the clutch removed. Any help would be much appreciated. Thanks!

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The clutch arm where the cable connects is on the left and it connects to the clutch via a shaft that pushes a rod which then pushes a ball bearing sitting in the holder and then the holder pushes the clutch operating plate to dis-engage the clutch. The only seal is on the clutch arm shaft that goes into the casing. At worst, only the springs on the operating plate would need to be removed then a 1/4" inward push on the rod from the right side would give clearance for the shaft to be inserted.
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Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock. www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx

A “very helpful” rating for this answer? Thanks!

Posted on Jun 11, 2009

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Posted on Jan 02, 2017

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1 Answer

How do you replace a clutch in a 1998-99 Geo metro


why not post symptoms first, (like, my clutch pedal is dead) or?
manual or automatic trans/ both have clutches.?????
metro ended in 97 and was then and a Chevrolet nameplate from 1998 to 2001
metro, is covered in all metro, FSM books
all metro forums
see vast links here
http://www.fixkick.com/swift.html

online:
and at alldata.com
mitchels.
dont know year, ?

my wild guess. on what is there, M/T stick shift car.

M/T stick
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:
    • Negative battery cable
    • Transmission assembly and matchmark the flywheel to the engine
    • Clutch pressure plate cover by slowly and evenly loosening the bolts until the spring tension is released
    • Clutch disc

Trans out,
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the transmission fluid.
  3. Remove or disconnect the following:
    • Negative battery cable
    • Both front wheels
    • Backup lamp switch electrical connector
    • Clutch release lever from the clutch release shaft
    • Clutch cable bracket and move it aside
    • Negative battery cable and hanger from the transmission
    • Gearshift guide case bolts and set the engine wire harness and bracket aside
    • Speedometer cable
    • Starter motor
    • Two right side upper case-to-engine bolts
  4. Install an engine support fixture.
    • Both drive axles after properly supporting the transmission
    • Flywheel cover
    • Control joint shaft through bolt and separate the control shaft from the control joint
    • Gearshift control lever guide plate and separate the extension rod from the lever guide plate
  5. Support the transmission.
    • Bolts from the rear transmission mount
    • Left side mounting bracket bolts
    • Right side case-to-engine mounting bolts
    • Transmission through the left side of the engine compartment and make certain that the input shaft clears the clutch pressure plate

Feb 14, 2015 | Geo Cars & Trucks

Tip

2004 Hyundai Tiburon Clutch.


First you need to remove the Transaxle.

Manual Transaxle System REMOVAL

1. Remove the engine cover.
2. Remove the battery terminal.
3. Remove the air duct.
4. Remove the battery tray.
5. Remove the air cleaner.
(1) Upper
(2) Lower
6. Remove the back-up lamp switch.
7. After removing the CKP sensor, O2 sensor and oil pressure switch wiring bracket, separate the connectors.
8. Remove the brake fluid leveling sensor connector.
9. Remove the speedometer driven gear connector.
10. Remove the clutch release cylinder mounting bolt.
11. Remove the cotter pin of the shift cable (transaxle side).
12. Remove the cotter pin of the select cable. (transaxle side)
13. Remove the clip of the shift cable (transaxle side).
14. Remove the clip of the select cable (transaxle side).
15. Separate the steering column shaft joint.
16. Separate the power steering oil pump hose.
Be careful not to leak after separating.
17. Separate the hose after removing the clip of the power steering return hose.
18. Remove the upper connecting transaxle bolt.
19. Separate the start motor.
20. Install the engine support fixture.
21. After removing the tire, remove the caliper.
22. Remove the transaxle side cover.
23. Remove the transaxle side under cover.
24. Separate the tie rod end.
25. Remove the wheel speed sensor and the knuckle mounting bolt.
26. Drain the oil.
27. Remove the transaxle mounting bracket.
(1) Insulator bolt
(2) Body side mounting bolt (Upper)
(3) Body side mounting bolt (Side)
(4) Transaxle side mounting bolt.
28. Remove the front roll stopper.
(1) Insulator bolt
(2) Stopper bolt (Upper)
(3) Stopper bolt (Lower)
29. Remove the rear roll stopper.
(1) Insulator bolt
(2) Stopper bolt
30. Remove the drive shaft.
31. Remove the front muffler.
32. Remove the sub frame mounting bolt.
33. Install the transaxle jack.
34. Remove the transaxle lower mounting bolt to the engine.
35. Remove the transaxle assembly.

INSTALLATION
Installation is the reverse of the removal.

Then inspect and replace the clutch place and pressure plate.

INSTALLATION
1. Apply multipurpose grease to the release bearing contact surfaces and the release cylinder contact surface of the clutch release fork assembly.
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage and judder.
2. Apply multipurpose grease into the groove of the release bearing.
3. Apply multipurpose grease to the clutch release lever fulcrum contact surface of the clutch release fork assembly.
4. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and make certain that all oil or grease has been removed.
5. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.
Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.
6. Using the special tool, install the clutch disc to the flywheel. When installing the clutch disc, be sure that the surface having the manufactures stamp is towards the pressure plate side.
7. Install the the clutch cover assembly onto the flywheel and install the six (6) bolts through the clutch cover into the flywheel.
8. Tighten the bolts by one or two turns at a time, in succession, to avoid bending the cover flange.
If a special tool is not available, tighten the bolt temporarily and then torque to specification in diagonal torquing sequence indicated below.
TIGHTENING TORQUE
Single mass flywheel:
15~22 N·m (150~220 kg·cm, 11~16 lb·ft)
Dual mass flywheel:
20~27 N·m (200~270 kg·cm, 14~19 lb·ft)
9. Remove the special tool.
10. Install the transaxle. (Refer to GROUP - Manual Transaxle Assembly)
11. Adjust the clutch pedal free-play. (See CH-6)
INSPECTION
1. Check the diaphragm spring end for wear and uneven height.
Replace if wear is evident or height difference exceeds the limit.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
CLUTCH DISC
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease, and replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc if it is out of specification
3. Check for torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.
CLUTCH RELEASE BEARING
The release bearing is packed with grease. Do not use cleaning solvent or oil.
1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
INSTALLATION
Installation is the reverse of the removal.
Then remove pressure plate and Clutch plate.

1. Insert the special tool (that came with your clutch kit) in the clutch disc to prevent the disc from falling.
2. Loosen the bolts that attach the clutch cover to the flywheel in a star pattern.
3. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

on Jan 13, 2010 | Hyundai Tiburon Cars & Trucks

1 Answer

2010 Kawasaki KX 85 clutch will not engage


Hi, Robert and the usual suspects are:
1. Clutch cable adjusted too tight.
2. Pressure plate center screw adjusted too tight
3. A broken clutch rod.
4. Slave cylinder piston stuck.
5. Clutch plate missing from the clutch pack.
6. Clutch plates have worn past minimum specifications.
7. Clutch plates crystallized due to incompatible oil.
8. Broken transmission shafts or gears.
9. Rear drive belt or chain broke.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Clutch does not engage
https://advrider.com/index.php?threads/clutch-problem-kawasaki-kx85.1017465
Kawasaki KX85 Service Manual
OEM Parts for Kawasaki
Kawasaki KX85 Owner Manual

Jul 03, 2013 | 2010 kawasaki KX 85

1 Answer

How do i change clutch release arm


I believe the arm is on top of the case on the left hand side attached to a shaft that goes into the case. It also may have a bolt in the side of the case below the arm that has a machined shoulder on it to retain the shaft from pulling out. If it does, remove it.If this is the way it's set up, it actuates the clutch thru a rod that goes all the way across the motor inside the hollow shaft that the clutch is mounted on. I don't have specific experience to the 250 KX, but I've been in the little ones and that's the way they're set up. So here's what you do-
Drain the gear oil and remove the round clutch cover on the right side of the bike. Remove the 5 or 6 washered bolts and the springs from the clutch pressure plate. Remove the pressure plate and you'll see the clutch lifter-it's a short rod with a flat bearing on it located in the middle of the clutch shaft. Remove it and using a small magnet tool go inside the hollow shaft and retrieve the actuating rod. There may be a ball bearing with it as well, although I don't think there is in that bike. Anyway, don't lose it if it has one and pay attention to which end of the shaft goes to the clutch arm. You can now replace the arm. When your putting it back together, rotate the arm with your fingers and make sure the lifter is moving up and down before you put the pressure plate and springs back in. Good luck!

Jun 13, 2011 | 2003 kawasaki KX 250

1 Answer

1991 Kawasaki KX 250 how to replace the clutch


Hi, Firefight685 for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
04 kx250 clutch installation help
Kawasaki kx250 clutch rebuild
https://www.scribd.com/doc/121008272/KX125-KX250-94-98-Service-Manual
OEM Parts for Kawasaki
1991 Kawasaki KX250 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e


May 18, 2011 | kawasaki KX 250 Motorcycles

1 Answer

Info on do it tyour self clutch removal on 2001 mustang 3.8


REMOVAL:
  1. Lift clutch pedal to uppermost position to disengage clutch and brake pedal pivot shaft.
  2. Push clutch and brake pedal pivot shaft forward and unhook clutch release lever cable from clutch and brake pedal pivot shaft and allow it to slowly swing rearward.
  3. Raise and support vehicle.
  4. Remove clutch release lever dust shield.
  5. Disconnect clutch release lever cable from clutch release shaft.
  6. Remove retaining clip, then clutch release lever cable from flywheel housing.
  7. Remove starter motor from flywheel housing, then engine rear plate to front lower flywheel housing bolts.
  8. Remove transmission.
  9. Remove flywheel housing back just far enough to clear clutch pressure plate, then remove housing.
  10. Remove clutch release shaft from flywheel housing by pulling it through window in flywheel housing until retainer spring disengages from pivot.
  11. Remove clutch release hub and bearing from clutch release shaft.
  12. Loosen six clutch pressure plate bolts evenly to release spring tension gradually and avoid distorting clutch pressure plate. If same clutch pressure plate is to be installed, mark plate and flywheel so pressure plate can be installed in its original position.
  13. Remove clutch pressure plate and clutch disc from flywheel.
INSTALLATION:
  1. Position clutch disc and pressure plate assembly on flywheel, noting following:
    1. Three flywheel housing to block dowels on flywheel must be properly aligned with clutch pressure plate.
    2. Bent, damaged or missing flywheel housing to block dowels must be replaced.
    3. tart clutch pressure plate bolts but do not tighten.
    4. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.
    5. Align clutch disc using suitable alignment tool inserted in pilot bearing.
    6. To avoid clutch pressure plate distortion, alternately tighten bolts a few turns at a time, until they are all tight, then tighten to specifications.

  2. Install transmission to flywheel housing.
  3. Install engine rear plate to flywheel front lower housing bolts, then connect clutch release cable to flywheel housing and connect retaining clip.
  4. Connect clutch release lever cable to clutch release shaft, then install clutch release lever dust shield.
  5. Install starter motor.
  6. Lower vehicle, then install clutch release lever cable as follows:
    1. Lift clutch pedal to disengage clutch and brake pedal pivot shaft.
    2. Push clutch and brake pedal pivot shaft forward and hook end of clutch release lever cable over rear of clutch and brake pedal pivot shaft.

  7. Cycle clutch pedal several times to adjust clutch release lever cable

Aug 08, 2009 | 2001 Ford Mustang

1 Answer

Clutch wont engage after kickstarter shaft installation.


The clutch lever must have been pushed in when i tried to install the push rod the first time so the push rod didn't get pushed in all the way.

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May 29, 2009 | 1996 Suzuki GSX-R 750 T

1 Answer

I need to tear down my transmission in a 1988 Chevrolet Cavalier Z24 2.8L i am fixing the clutch and i need diagrams on how to take it apart and put it back together


Below is process for removing and replacing the clutch assembly.
Hope this helps, good luck.
Regards,


REMOVAL & INSTALLATION


See Figures 1, 2 and 3



0900c1528003be16.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 1: Exploded view of the clutch disc and cover assembly
  1. Disconnect the negative battery cable.
  2. If equipped with a cable clutch (1982-84 vehicles), disconnect the cable at the clutch release lever and transaxle, as outlined earlier in this section.
  3. For 1985-94 vehicles remove the sound insulator from inside the vehicle. Disconnect the clutch master cylinder pushrod from the clutch pedal.




0900c1528003be17.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 2: Disconnect the clutch actuator (slave) cylinder line - 1995-96 vehicles
  1. Remove the transaxle, as outlined earlier in this section.
  2. Mark the pressure plate assembly and the flywheel so that they can be assembled in the same position. They were balanced as an assembly at the factory.
  3. Loosen the attaching bolts one turn at a time until spring tension is relieved.
  4. Support the pressure plate and remove the bolts. Remove the pressure plate and clutch disc. Do not disassemble the pressure plate assembly; replace it if defective.
  5. Inspect the flywheel, clutch disc, pressure plate, throwout bearing and the clutch fork and pivot shaft assembly for wear. Replace the parts as required. If the flywheel shows any signs of overheating, or if it is badly grooved or scored, it should be refaced or replaced.




0900c1528003be18.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 3: You must follow the specified sequence when tightening the pressure plate retaining bolts
To install:
  1. Clean the pressure plate and flywheel mating surfaces thoroughly.
  2. Position the clutch disc and pressure plate into the installed position, and support with a dummy shaft or clutch aligning tool, tool J 29074 or equivalent. The clutch plate is assembled with the damper springs offset toward the transaxle. One side of the factory supplied clutch disc is stamped "Flywheel Side".
  3. Install the pressure plate-to-flywheel bolts. Tighten them in the sequence shown in the accompanying figure, as follows:
    1. Tighten bolts 1,2,3, then 4,5,6 in the sequence shown to 12 ft. lbs. (16 Nm).
    2. Tighten bolts 1,2,3, then 4,5,6 in the sequence shown to 15-22 ft. lbs. (22-30 Nm) plus an additional 30° turn.
    3. Remove the clutch alignment tool.

  4. Lubricate the outside groove and the inside recess of the release bearing with high temperature grease. Wipe off any excess. Install the release bearing.
  5. Install the transaxle, as outlined earlier in this section.



WARNING When adjusting the cruise control switch, do NOT exert an upward force on the clutch pedal pad of more than 20 lbs. (89 N) or damage to the master cylinder pushrod retaining ring may result.

  1. For 1985-94 vehicles, attach the clutch master cylinder pushrod to the clutch pedal and secure with the retaining clip. If equipped with cruise control, check the switch adjustment at the clutch pedal bracket. Install the sound insulator.
  2. If equipped with a cable clutch, attach the clutch cable at the transaxle and clutch release lever. Check the clutch operation by lifting the clutch pedal up to allow the mechanism to adjust the cable length. Depress the pedal slowly a few times to set the pawl into mesh with the quandrant teeth.


ADJUSTMENTS


All 1982-84 models have a self-adjusting clutch mechanism located on the clutch pedal, eliminating the need for periodic free play adjustments. The self-adjusting mechanism should be inspected periodically as follows:
  1. Depress the clutch pedal and look for the pawl on the self-adjusting mechanism to firmly engage the teeth on the ratchet.
  2. Release the clutch. The pawl should be lifted off of the teeth by the metal stop on the bracket.

On 1985 and later models, the hydraulic clutch system provides automatic clutch adjustment. No adjustment of clutch linkage or pedal position is required.

May 04, 2009 | Chevrolet Cavalier Cars & Trucks

1 Answer

How do you replace clutch in 1997 toyota corolla? Do you need to replace entire clutch assy or just the clutch disc?


I see. sounds like you need a new clutch. OK, here is a step by step guide to follow. it will help with the removal and installation of your new clutch.

Remove the Old Clutch Step1 Verify that your vehicle's clutch is the source of your problems and not the pedal-arm bushings, activating cables or the slave-master cylinder. Step2 Unhook the positive battery cable, the clutch cable or hydraulic slave cylinder to get the transaxle ready for easy removal. Eliminate anything that may hinder your efforts, including exhaust pipes and the speedometer. Step3 Secure your car in a safe position before jacking up the front end. Step4 Stabilize the engine with a jack below the oil pan. Remove the transaxle by undoing at least one engine mount. Step5 Separate the engine from the transaxle by removing the bolts that surround the flywheel bell housing. Step6 Push the transaxle away from the engine until the input shift clears the pressure plate. Step7 Disengage the bolts surrounding the pressure plate and take it and the clutch disc out. Check to see if the flywheel's friction surface is scored, checked or has hot spots. Remove, machine and reinstall the flywheel, if needed. Step8 Examine the pilot bearing (bushing) located at the flywheel's center to be sure the needle bearings are lubricated and that there's no galling. Also look for any oil leaking around the rear main engine seal. Replace the clutch Step1 Follow the instructions for replacing your car's clutch carefully to avoid having to remove the transaxle. Step2 Check that the transaxle's input shaft isn't leaking; replace if needed. Step3 Take out the flywheel and the old seal and install a new seal. Install a New Clutch Step1 Clean the crankshaft flange before putting in the flywheel. With the flywheel on top of the flange, secure the bolts in a star formation to the specified torque for your vehicle. Step2 Install the clutch disc and pressure plate. Prior to putting in the transaxle, attach the new release bearing to the release fork. The fork should move freely. Step3 Hoist the transaxle into position and move it forward until the input shaft glides into the clutch disc's spindled hole. Do not apply force. Step4 Reinstall any bolts or mounts that were removed to replace your car's clutch. Grab the transaxle, release the jack and lower your vehicle. Step5 Consider replacing your car's clutch cable. If you don't replace the cable at least adjust it for the right amount of free-play. Step6 Confirm that your clutch's self-adjusting action is performing correctly by depressing the slave cylinder's piston into its bore. Step7 Drive your car to be sure your clutch is working properly.


PLease rate and god bless:)

Apr 03, 2009 | 1997 Toyota Corolla

1 Answer

1991 KX 250 super tight clutch


sounds like your clutch springs are old they tend to get hard as they get old. but even with the good springs you cant move the shaft with your hands . take the clutches and basket out its not hard just remember how it comes apart lol

Jan 21, 2009 | 2002 Honda Civic

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