I recently bought a 1984 Honda XR250 incomplete bike, was told by owner that it may have the wrong clutch because the small gear on the back of the clutch basket does not mesh with the idle gear between the kickstart and clutch. I was told that the letters KT1 stamped in the clutch basket ment it was for a 1986 model and onwards, I have since purchased another clutch from a 1985 XL 250 with KK1 stamped on it, which I am told is the right clutch but it also does not mesh with the idle gear. The small gear on the back of the KK1 clutch is the same as the gear on the KT1 clutch. If it helps at all the idle gear has 27 teeth and meshes fine with the kickstart gear, and the clutches both have a 15 tooth gear. Would appreciate any advice on this matter.
The kick shaft gear, idler gear, and clutch drum gear on the 1985 xr250 and below are smaller tooth gears than 1986 and newer. I have an 85 and an 88. I had to replace the 85 kick gears 3 times. The last time I replaced them I found that the larger gears on the 88 fit as long as you replace only the gears. The kick gear comes off the shaft and the larger tooth gear fits on the shaft. The larger idler gear fits where the smaller tooth idler was and the drum gear comes out and the larger tooth gear will fit there. Or the drum you have with the larger gear will now fit the other gears. This is a better solution than finding another drum with the smaller tooth gear because the smaller tooth gears will not last. I hope this helps.
Testimonial: "Thanks Sam but i have got onto another clutch basket with the right gear on it. like your idea and will keep it in mind for future fixes, thanks mate."
Sounds like the idler gear may be the incorrect gear
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