Hey Fellow Riders bare with me please!
I just bought a 1979 KL 250. Been running pretty good for the past two weeks. Then of wammoo.. Just when you start getting used to all the fun.

Anyways, I was riding to a buddys.. I was going about 35. I heard a weird tinging type of noise, not loud just noticeable (heard it before didnt think much of it) . I let off the throttle and pull in the clutch, then the bike died. I was still coasting in 4th gear. I figured i would bump start it. I popped the clutch out and the tire locked up. Skidded to a stop, got off the road. Luckily an older guy riding a bike came to give me a hand.

While pulling in the clutch in 1st gear I tried to kickstart bike and the clutch felt like it wouldnt engage, the wheel would spin like the clutch was out and in gear.

I got the guy to help me bump start the bike somehow with no clutch working.. Now as i took off, I had to pull IN the clutch for it to engage to the wheel. WTF
after a few times of working the clutch on and off on my way home, It went back to Normal!!! A few blocks from my house the bike gradually would not accelerate and up a hill it clonked out.

I checked the clutch and the linkage, friction discs are intact and look fine.
Now it seems the bike is harder to push in gear with the clutch in. Still fine in neutral.. Cant kickstart the bike, but have bump started it down a hill and got to stay running for a minute or so, when i let off it dies.. So im stumped.
Did I fry my trans? The engine still has compression, fuel, and spark. Any ideas?
Thanks you

 

anybody got any clues to where to start looking.. Also has anybody just got the nut for the flywheel removal from the hardware store?

 

When you pulled the clutch cover off, did you find metal particles in the oil? If so, I'd be pretty careful about running the engine because the crankshaft uses the same oil as the trans. I'd think if the trans was fryed, you'd find shavings in the oil. There's also a shaft that actuates the clutch on the mag cover. If it has dirt in it or is dry, it will cause the clutch to hang up. If you are looking for a service/repair manual for the bike, there are a number of factory ones on ebay. I have a 78 kl250. I'm currently chasing electrical gremlins on mine. If you have extra parts, PM me. I might be intrested in buying them. Jim

 

Jim

Thanks for your response!
I did not find any shavings in the oil thankfully. Thats what I was afraid of.. I finally got the fly wheel off and stator plate.. Boy is one of my coils fried. You know anywhere that will rewind them?
As of now im cleaning everything up, going to try some fresh oil and the stock exhaust and clean and lube clutch shaft..

Hows your bike run, any modifications? I dont have much spare parts hit. Original dual rate springs and exhaust.. Any tips for me? When do you run the "en richer" on the carb?

 

Whats the most harm you can do from bump starting a bike? Its already in gear, so i would think mainly just the clutch.. what else

 

Check on ebay for the coils etc. You'll be surprised how much stuff is on there for these old bikes. There are a number of motor cycle junk yards that advertise parts for them there. I've bought a new rectifier/regulator, mag cover, I'm currently bidding on a factory service manual for mine. Search on 78 and 79 KL250 and there will be like 20 pages of assorted parts and pieces. A good cheap/quick way to richen the carb is to drop the jesus clip on the needle down a groove. This opens the main jet sooner and will richen the mix at 1/4 to half throttle. Othewise a new jet would be required for full throttle. Also if you have the carb off, remove the main jet and see it's not partially clogged. Crap in the jet will make it run lean.
Mine runs like a top, I am just having trouble with the lights blowing bulbs. I dropped the clip on the needle on mine, got a can of spray carb cleaner at Autozone and shot it through the jets followed by compressed air and it really smoothed it out. I also put a small inline filter between the tank and carb. If you buy any parts on ebay, make sure you get 78, 79 parts. Some will tell you that the parts from early 80s will work, but is often not the case. Good luck! Jim

 

Oh, and I raced a number of 70s era bikes in their day and ride them still. I 've bump started every one I owned a number of times and the only damage occurred when I skidded the back wheel and fell over!! Jim

 

Bump starting a bike is just as normal as kicking it or hitting the start button. I do it all the time when I'm out riding. Just pick the right gear for the speed and material you are riding on.

 

Oh and I forgot......welcome to the forums.

 

Well quite an update! I got the bike running. It was the timing, point where never opening. I pretty much gave up, wAs all ready looking for a new kawasaki.
I made it so they opened and the bike fired first kick. Does anyone know what the gap should be on the points. I'm getting gauges tommarow.
Also some bad news as I was re sealing and fixing my kickstarter spring I noticed that the kickstarter must have kicked back and took a huge chunk out of the upper part of where the kickstarter spindal sits. I got the chunk of metal out of my case . Fortunately the thing still holds but who know for how long. Any one had this happen? Now sometimes I hear a pinging sound like something flying around in the case, more chunks? Can that get up in the piston head? Could it be my valves? ****in motorcycles ! Learned a lot in the past 2 days lol