Clutch

Hey. I have a kz250 that just keeps causing problems, first of all my clutch isnt engaging at all the clutch rod doesnt seem to move or something.

Seccond the engine starts and stalls as soon as I let go of the throttle and depending on where the choke is no matter how much gas i give it it doesnt rev higher plus its really loud.
Any advice would help alot. Thanks

If the clutch will not engage at all (acts like the trans is in neutral), the clutch cable could be adjusted way too tight, the release mechanism could be broken or rusted. Much less likely, the clutch hub nut could be loose, or the clutch could be missing.

Carb may need a thorough cleaning and adjustment, and the carb holder may need replacing.

Install a muffler.

Has all the routine maintenance been performed? Is the factory air box in place?

The KZ250 clutch release is different from most KZs, but it's kind of similar to some of the shaft drive models. With that type you usually adjust the cable & if that doesn't work the cable may be stretched so you'd replace the cable. This is assuming the clutch release mechanism is properly installed & not damaged.

I don't know anything about the 250, but from the diagrams at Partzilla, the clutch release lever mates to the clutch release shaft. check that the splines aren't stripped & make sure the bolt is tightened properly. There's another bolt that appears to be a dog bolt. The end of the bolt fits into a groove on the clutch release shaft & I think it keeps the shaft from moving up & down.

There's a long push rod & a short push rod. The short push rod has teeth that mesh with the clutch release shaft. make sure the teeth on each part aren't worn or broken. Maybe the short push rod is missing?

Just to be sure we are on the same page, when you are riding down the road and you are not touching the clutch lever, the clutch is ENGAGED and transmitting power to the transmission output shaft.
When you squeeze the clutch lever, the clutch cable pulls the release mechanism, thus DISENGAGING the clutch so that the motorcycle can be stopped with the engine running and the transmission in gear.
Not squeezed = engaged
Squeezed = disengaged

You should not touch the throttle when starting the engine. The starting and running problems you describe could be caused by several problems, such as clogged pilot circuits, leaking carb holder and adjustments that are way out of spec. If I had to bet on a single cause, I'd put money on a recently removed air box.

Alright texaskz i have adjusted the clutch cable and it still wont disengage so i will try to find the clutch hub nut and what does a air box look like? And when i pull the clutch lever the clutch does not engage

Okay martin_csr i will try to locate these bolts and i cant find the short push rod does that go infront of the long one or do you know where i can find it?

Kawi-problems23 wrote: Alright texaskz i have adjusted the clutch cable and it still wont disengage so i will try to find the clutch hub nut and what does a air box look like? And when i pull the clutch lever the clutch does not engage

When you pull the clutch lever it is not supposed to engage. When you pull or squeeze the lever it is supposed to disengage.
Forget the hub nut until tou are absolutely sure that the release mechanism is functioning properly.

An exploded view of the air box is at the link below. It is what the air cleaner goes in.
www.kawasaki.com/Parts/PartsDiagram/142244/1980/KZ250-D1

Kawi-problems23 wrote: Okay martin_csr i will try to locate these bolts and i cant find the short push rod does that go infront of the long one or do you know where i can find it?

The release mechanism is numbers 10 - 15
www.kawasaki.com/Parts/PartsDiagram/142237/1980/KZ250-D1

Try this

www.kzrider.com/modules/ServiceManuals/K...0KZ250%20-%20305.pdf

Or this

www.scribd.com/mobile/doc/34889983/Kawas...-a-82-Service-Manual

Or this

www.autorepairmagz.com/search/kawasaki+kz250+manual+download

The KZ 250 D1 has a unique clutch actuator gear push rod system, this is Kawi-problems23 mayor problem.
my thought is:
He has to adjust the gear on rod #12 with gear push rod #14.
Loosen screw #17, pull out #12, push in #14 to get in touch (pressure)push rod #15 and then put in #12 to a 90 - 100 degree angle.
or readjust lever #11 on rod #12

Thank you so much for all the advice and the service manual everyone i am going to look at the clutch again right now.

What exact year & model is your 250? Was the clutch working fine before the problem came up?
From the diagrams the 80-81 clutch release is completely different from the later models.