1996 Klx 250 gearbox problem
 

Just to start off hi new here so be gentle,

I bought two klx 250 one is 1996 only 21000 in very good condition with a gearbox problem, the other is 1998 thats got 32000 miles not so good condition but engine box excellent condition,

What the 1996 klx is doing it runs very well when I get it started so carbs need cleaning but that's another post, when I start the bike in neutral then put it in first start to ride the bike I can get it sometimes up to third then it will start to wind with no drive in any gear, when I stop and try find neutral the light come on and it's still wineing when I let the clutch out, if I put it into first the wineing stops as though its in neutral, it I leave it for a day or so it will find a gear then do exactly the same when I ride it.

I'm making one good bike to do green lanes, the other I'm stripping down to do a full rebuild to have a show piece, any help would be a great hope, not much experience with these gearboxes

Sounds to me like the clutch has given up or someone put the wrong oil in it. Will it shift through the gears without any load?

Yes, sounds like a clutch issue to me also.
Do you know how to open the side to get at the clutch, inspect plates, etc? Do you have access to a factory service manual?
Also check to see that your clutch cable isn't overly tight. There should be a little bit of slack when the lever is fully released.

I check that, I've got the engine on the table in the workshop as I need to replace the spline that rounded off so may as well do that, I think it's more that just a cable, I'll go inside have a look at the clutch,

Just wandering if someone had a engine block of a older klx mines a 1996 that may be a better option or a complete engine I would have that

Changing a clutch is simple and all bikes will require it at some point, some quicker than others as people ride differently.

Any chance that the oil is synthetic that was not intended for a wet clutch? Some of the oils have friction modifiers in them and the clutch slips.

Ride on
Brewster