Clutch actuator lever 86 Tecate KX250

[nd4speed]

My clutch cable broke on my 86 KX250 last weekend because the clutch actuator arm lever that pushes the clutch pushrod and pressure plate is too far forward pointing towards the front wheel.

With this actuator arm too far forward it rubs on the clutch cable and the new clutch cable I tried to put on today is too long because the arm does not spring back towards the rear wheel with the pressure of the clutch springs.

The clutch basket is not grooved. I pulled up the lever and it is not grooved or worn bad.

Is this a common problem like the pushrod is bent or worn?

This should also relate to 1985-1986 KX500 motors also.

The cable broke after like 5 minutes of use and I used a small band clamp on the arm with the frayed end jammed into the clamp and tightened into the screw.

[sblt500r]

the push rod would be worn. they need an adjuster like the triz's on the pressure plate.

do you have the steel ball in there?

[nd4speed]

Well I guess it's a no brainer. Obviously there is a problem with either the push rod or ball bearing. I have never taken any of it apart and rode it for a couple years before this problem.

I seem to remember reports of bent push rods. I guess a stack of clutch plates that were too large of something might have this affect but it has been fine until now, although clutch cable adjustment has been near the max since I've owned it.

Really don't look forward to taking it apart again (and the parts trans). I just replaced the forks. But it's old and cheap, what more would one expect?