Hi everyone,

I have been trying to get hold of a manual in the UK for a KH125 neither Haynes or Clymer do one and the only other alternative is a genuine Kawasaki dealers workshop manual priced at £40.00 or roughly $70.00 so if anyone khows of another publisher that does one then I would appreciate your input.

The problem I have is when I stripped the clutch down and replaced the plates I put it back together in the order that I dismanteled it (or so I thought) and there is nothing at the lever it goes straight back to the bars. After taking up the slack at the lever adjuster it is solid.

Now either I have put this back together wrong or lost something out of the workings, but after taking it apart again and carefully looking at it I can only see one way in which it can fit.

There is the main clutch basket which fixes onto the gear layshaft with a circlip

another circlip which seems to act as a spacer

the inner basket which is in two parts with the metal and cork plates in between

Circlip to hold inner basket onto shaft

6 springs and bolts and an outer plate

Ballbearing to go inside gear layshaft, clutch push rod, and one more ballbearing to fit inside of pushrod that comes into contact with the clutch ratchet mechanisim

Anyone know about Kh125s? or even better still if anyone in the trade can get hold of an exploded diagram then that would be brill there is a possibility that the clutch set up on the KE/KH100 might be the same.

I am stumped and it's got to be something and nothing it's just putting my finger on it.

I suspect that there are two parts to the pushrod with the first ballbearing in between maybee someone can clarify this

I would be very greatful for any help

Allan

 

Something like this?
hmm, that did not work

 

Lets try this again.

 

Dragone#19 you are a true super star,

Thanks a lot for taking all the trouble to up load the exploded diagram.

The model that I am working on is an earlier version 1991 but looking at the diagram the clutch unit is more or less the same.

I have assembled this correctly so the only possible cause is the pushrod and ratcet mechanisim and seeing as I havent touched the ratchet then my guess is the pushrod which brings me back to the begining of the thread (have I lost something) I don't suppose that you have a diagram of the pushrod set up if so I would really appreciate it.

Thanks again much obliged

 

Here is the link where I obtained the fiche. http://www.flatoutmotorcycles.com/fi...ion_detail.asp

This is of the KE100, I have not found any KH stuff. Ron Ayers also has a fiche but with the same results.

This is about all I have come up with in my searches so far. Besides what the ride looks like and manuals available.

 

Thanks for your help Dragone#19,

I think I will be able to put this to bed now

 

I have sorted this out now and it is working perfectly so thanks for the help and for putting me in touch with that website I have put it into my favourites and will certainly be using it again

Thanks 59allann