2000 EX250 Clutch/Gear issues after sitting

JasonJ · July 7th, 2014, 06:59 PM

So my brothers 2000 Ninja 250, which ran and shifted perfectly a couple months ago is now mine.

Bikes got just over 1800 original miles, all fresh fluids, good shape other than farings and such.

I replaced the clutch lever which had the end snapped off. After that, I noticed that the clutch didnt seem to be disengaging when the lever was properly adjusted to 2-3mm freeplay and slack taken up at the lower adjuster.

If I put the bike into 1st gear, there is little to no difference when pulling the clutch lever and trying to roll the bike, it should roll freely. I opened the oil filler cap, looked in while pulling the clutch lever, and can see the pressure plate releasing and the clutch discs moving. Also cannot engage 2nd-5th gear. Only neutral and 1st.

SOOOOO I go and get desperate and pull the clutch cover off, oils drains of course. I pulled the pressure plate off, removed all clutch discs as an assembly, check them out.. all look GREAT. Place them back in the clutch basket (ive done clutches before, and kept these all in the proper order too). Reassembled.

Now it feels like the clutch isnt engaging enough, but still makes little to no difference rolling in 1st and 1st with clutch lever pulled.

Any thoughts other than to go back in, loosen and double check the torque in the pressure plate bolts (and replace gasket for clutch cover) ???

JasonJ · July 7th, 2014, 07:03 PM

P.S.

I did read while researching that Kawasaki clutches stick often, and when cold, or after sitting the outer clutch disc will release with the pressure plate, but the others do not until the engine and oil is warm and they separate and act normally.

Any truth to this?

Motofool · July 7th, 2014, 07:13 PM

Quote:

Originally Posted by JasonJ

..........Also cannot engage 2nd-5th gear. Only neutral and 1st..........

That is normal, Kawasaki's device prevents that from happening, unless the sprocket is rotating pretty fast.

Yes, the discs can remain as a package sometimes: vibrations and heat will make those get apart.

Sometimes it is just the type of oil.

JasonJ · July 7th, 2014, 07:19 PM

Thanks.. I dont have much specific knowledge of the idiosyncrasies of the 250 ninja.

Maybe I'll just open up the clutch cover, properly torque the pressure plate, and put a new gasket on with new oil.

I JUST rode the darn thing around the yard a month or two ago.. was perfectly fine. weird...

Motofool · July 7th, 2014, 07:53 PM

Quote:

Originally Posted by JasonJ

Thanks.. I dont have much specific knowledge of the idiosyncrasies of the 250 ninja.

Maybe I'll just open up the clutch cover, properly torque the pressure plate, and put a new gasket on with new oil.

I JUST rode the darn thing around the yard a month or two ago.. was perfectly fine. weird...

I don't believe that you need to open that cover again.

http://faq.ninja250.org/wiki/Acceler...oving_to_shift

Check this case out:
https://www.ninjette.org/forums/showthread.php?t=182263

JasonJ · July 8th, 2014, 04:21 AM

eh, I kinda do.. the gasket tore a bit when removing and I didnt have another one, so its got a tiny leak now, and I am sure the clutch pressure plate spring bolts are not torqued properly.

InvisiBill · July 8th, 2014, 05:29 AM

This is fairly common on the 500. The discs just get sticky after sitting for a while. The solution on those is to put the front tire against a wall and rev it up until it breaks itself free. However, the 500's clutches are known to be overkill for the bike, and I'm not sure how the 250's compares...

July 7th, 2014, 06:59 PM	#1
JasonJ ninjette.org member Name: Jason Location: Bay City, MI Join Date: Apr 2014 Motorcycle(s): 1980 Yamaha XS850G Midnight Special, 32k Miles; 2000 EX250F, <5000 Orig Miles Posts: 98	2000 EX250 Clutch/Gear issues after sitting So my brothers 2000 Ninja 250, which ran and shifted perfectly a couple months ago is now mine. Bikes got just over 1800 original miles, all fresh fluids, good shape other than farings and such. I replaced the clutch lever which had the end snapped off. After that, I noticed that the clutch didnt seem to be disengaging when the lever was properly adjusted to 2-3mm freeplay and slack taken up at the lower adjuster. If I put the bike into 1st gear, there is little to no difference when pulling the clutch lever and trying to roll the bike, it should roll freely. I opened the oil filler cap, looked in while pulling the clutch lever, and can see the pressure plate releasing and the clutch discs moving. Also cannot engage 2nd-5th gear. Only neutral and 1st. SOOOOO I go and get desperate and pull the clutch cover off, oils drains of course. I pulled the pressure plate off, removed all clutch discs as an assembly, check them out.. all look GREAT. Place them back in the clutch basket (ive done clutches before, and kept these all in the proper order too). Reassembled. Now it feels like the clutch isnt engaging enough, but still makes little to no difference rolling in 1st and 1st with clutch lever pulled. Any thoughts other than to go back in, loosen and double check the torque in the pressure plate bolts (and replace gasket for clutch cover) ???

July 8th, 2014, 05:29 AM	#7
InvisiBill EX500 full of EX250 parts Name: Bill Location: Grand Rapids-ish, MI Join Date: Jul 2012 Motorcycle(s): '18 Ninja 400 • '09 Ninja 500R (selling) • '98 VFR800 (project) • '85 Vulcan VN700 (sold) Posts: A lot. Blog Entries: 1 MOTM - Aug '15	This is fairly common on the 500. The discs just get sticky after sitting for a while. The solution on those is to put the front tire against a wall and rev it up until it breaks itself free. However, the 500's clutches are known to be overkill for the bike, and I'm not sure how the 250's compares... __________________________________________________ * Unregistered, I'm not your mom and I'm not paying for your parts, so do whatever you want with your own bike. *

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July 7th, 2014, 07:03 PM	#2
JasonJ ninjette.org member Name: Jason Location: Bay City, MI Join Date: Apr 2014 Motorcycle(s): 1980 Yamaha XS850G Midnight Special, 32k Miles; 2000 EX250F, <5000 Orig Miles Posts: 98	P.S. I did read while researching that Kawasaki clutches stick often, and when cold, or after sitting the outer clutch disc will release with the pressure plate, but the others do not until the engine and oil is warm and they separate and act normally. Any truth to this?

July 7th, 2014, 07:19 PM	#4
JasonJ ninjette.org member Name: Jason Location: Bay City, MI Join Date: Apr 2014 Motorcycle(s): 1980 Yamaha XS850G Midnight Special, 32k Miles; 2000 EX250F, <5000 Orig Miles Posts: 98	Thanks.. I dont have much specific knowledge of the idiosyncrasies of the 250 ninja. Maybe I'll just open up the clutch cover, properly torque the pressure plate, and put a new gasket on with new oil. I JUST rode the darn thing around the yard a month or two ago.. was perfectly fine. weird...

July 8th, 2014, 04:21 AM	#6
JasonJ ninjette.org member Name: Jason Location: Bay City, MI Join Date: Apr 2014 Motorcycle(s): 1980 Yamaha XS850G Midnight Special, 32k Miles; 2000 EX250F, <5000 Orig Miles Posts: 98	eh, I kinda do.. the gasket tore a bit when removing and I didnt have another one, so its got a tiny leak now, and I am sure the clutch pressure plate spring bolts are not torqued properly.