kawasaki KX 250 - Recent Questions, Troubleshooting & Support

Sometimes you need input rotation to properly align gears spin the crankshaft a little then try.

Are you sure the torque specs posted are correct? They seem a little strange to me

Here's how I'd try to fix the clutch: 1.) Try to adjust the cable at the handlebar; usually there's a little bid of clutch lever travel (like 1/4"-1/2") before the clutch disengages. For right now, adjust the clutch so that there isn't any play and the adjustment all the way out. If the clutch disengages the transmission, then you know you have to fiddle with the cable to get it adjusted properly. 2.) The clutch plates could be sticking: here you'd have to take the clutch cover off and get to the clutch. Remove the clutch (usually an impact is ideal for removing the clutch holding nut. Take the clutch apart (steels and clutches), make sure they aren't sticking together. Then dip the clutches in oil, then reassemble. 3.) Sometimes the clutch basket (holds all of the clutches and steels in a "basket") gets grooves in it. These grooves prevent the clutch from disengaging. Sometimes you can file the clutch basket fingers down to remove the grooves. Alternatively, if the clutch basket fingers are really worn, you may have to replace the clutch basket. Typically, when your in the clutch side of the engine case, I'd examine 2 and 3 (above) at the same time.

1996 KX250T

check for the fuel filter in the bottom of the gas tank attached directly to the outlet

it probably needs a clutch adjustment. try rocking it hard up,down side to side while changing gears. some peopl ecall it transmission lock.

Hello have you try draining excess oil from engine, I would try that first and see if you can kick it . I’m happy to assist further over the phone at https://www.6ya.com/expert/michael_18b4936ebf017b21

most ignition problems are simple 3 parts - fuel / fire / air from everything you've already worked on, it seems you must set your IGNITION to FIRE on time at higher rpm .

chuckbolton9 --I bought mine on ebay, i have a cannondale 440 ex that was hard to find , but i did on ebay ,cost me around 19.99 p;us 5.00 for shipping.Well worth the 24.99!

burn out silencer packing or exaust leaks can burn a sparkplug , i guess your exaust system have lots of leaks that make the sparkplug fool and burn

First, did it break or is it bent or is it stripped? These all require different approaches once you get the right side of the engine clear, clutch removed, etc... TAKE PICTURES WHILE YOU ARE DOING THIS to make sure you put everything back where it belongs. Do you have a clutch hub holder? (IMPORTANT) Do you have a air wrench, you will have a large clutch nut (24-26MM?) to remove and then reinstall the nut with the correct torque! If you do not have these tools, PLEASE take it to a PROFESSIONAL. He will have all the tools necessary. If the shift shaft is broke or bent it is going to be more difficult because it is a tight fit through the engine cases, they are aluminum and they will break if the shaft is forced out!! You will have to carefully saw the shaft off CLOSE to the case as possible before attempting to remove it. If its just stripped, it can be filed or sanded down, cleaned, and removed easily. Change the shift shaft seal too!!! If this is your first time to try this... and you don't have any of the tools I mentioned, PLEASE take it to a professional!!

Sounds like a valve timing problem to me. Put the engine at TDC (top dead center). There will be marks on the cam gear that should be aligned with the top of the head casting. This is something that could be damaging to the engine so be careful. A manual is a good investment.

Bent shift fork is your problem.1st and 2nd working fine,wont go into 3rd,replace the shift fork and stop being so hard on the shifter.Costs a lot of money to fix these toys.