Your ok on oil. There are some oils with friction modifiers that are so slick that they can make clutchs slip. Oil designed for bikes do not do that.

 

How many miles to you typically get out of a klx clutch. Mine is around 12k miles on the factory clutch. It still feels great.

Was wondering if I should be prepared to change.

Bike was ridden on the street 100% before I bought it. Now it's more like 50/50

 

Mine's still good at 51,000 miles.

 

Here's what appears to be a good clutch inspection/maintenance/repair thread with pics. Think I will try new Barnett springs first and see what happens. This thread shows the stock springs being out of service spec. Maybe a typical issue with the KLXs?

Kawasaki KLX 250 Clutch Disassembly, Inspection and Replacement | GT-Rider.com

 

just did the clutch on my sons bike, the springs were about 2-3mm shorter than spec. we also changed out the fibre plates as he'd burnt most of them pretty good.......

 

Never had clutch slip until the bb351 was installed at around 17000 miles a few days ago. At first I thought I was not fully releasing the lever but as the BB351 breaks in more fully I find more and more slippage as I get more rambunctious with the throttle. I just ordered some Barnett clutch springs; hope that cures the issue, else I guess I'll have to get the rest of the clutch consumables too. I guess EBC is the way to go?

 

Really, a clutch upgrade should be considered mandatory at time of BB install - at least the Barnett spring kit.

The 351 increases the TRQ curve so radically - and down low - that eventual failure with spirited riding is pretty much a given..

 

Ok folks...
So I am doing a tear-down rebuild on a second hand KLX250sf...I'm re-doing the BB351 as it had some pretty heavy carbon build up and scoring, so I decided to go ahead and do the Barnett Spring replacement.
Once I got the oil out...which looked fine...I popped the clutch cover off and found this.






It seems like it is some kind of thin snotty grease...it's not the normal oil/water choco-milk. Assembly lube? I don't think that should be in there??

Thoughts?

 

Is the clutch haunted, it looks like you need 'ghost buster' treatment.

 

Snort....or maybe in a "Adult Situation".

I am worried there is a coolant leak, but I didn't do the original tear-down of the bike. I mostly mess with air-head boxer motors, so this Liquid Cooled voodoo is new to me.

Again, the oil from the sump looked ok, the only place I am finding this is inside the clutch cover so far.