I have a 98 KX250 that slips in 4th gear when the bike is on the pipe. I can cruise around in 4th gear without problems. It doesn't slip in any other gears.
The problem started when I noticed the clutch slipping at the track 1 day. The rubber fill plug broke and was leaking oil. I installed a new White Bros. clutch kit and it still slipped. The oil was filthy after only 5 laps. I took the clutch apart, sanded the fibers on a glass plate, filed the clutch basket smooth(it wasn't that bad), installed kx500 springs and fresh Maxima 80 wt oil and it still slipped.
So I took it apart again. This time I had the clutch hub and pressure plate faces glass beaded, put in new OEM fiber and steel plates, the 500 springs and Bel Ray 80 wt oil. The clutch didn't slip after 6 laps. I pulled in to check the oil and adjustment. I went back out and the clutch started slipping after about 5 more laps.
I took it apart again, very carefully inspected and measured everything and couldn't find anything obvious. Actually I've taken it apart and inspected it about 10 times over the course of 3 months.
I was an auto mechanic for 8 years so I have pretty good mechanical ability and I have the service manual. This has me completely stumped. I called Hinson and they said it could be the basket but I dont want to spend another $200 and not fix it. The basket is still within spec after mild filing. Is there some way it could be trans related? It has never popped out of gear.
I have an 03 KX250 and am thinking about putting the entire clutch assembly (from the basket to the springs) into the 98 and vise versa and changing one part at a time until it starts slipping. That's if the clutch assemblies interchange. Plus it's gonna take a long time to test each part 1 by 1.
If anyone has any advise I'd appreciate it. Thanks.