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Message: [QUOTE="IndyMX, post: 1357687, member: 71057"] When you pull apart an engine like this, make sure that you have plenty of room to lay out the parts. A 6 foot table is best.. Then as you take things apart, you can segregate the old parts from the new ones. Plus you have a nice clean area to work. I tend to never throw away old parts until the new ones are in the bike. It just helps my own mental health to know that the new one is working.. Also, take pictures along the way so that you can see how things go back together. So.. about the shifter. If you follow the shaft thru the engine (mentally, you don't have to take it apart), you will see that it has a mechanism on the clutch side of the engine with a spring on it. so that when you push the lever, it returns. At the end opposite the shaft, of that mechanism there is a pawl that moves the shift drum. This is what turns inside the trans that moves the shift forks. ([url]http://www.bikebandit.com/houseofmotorcycles/kawasaki-motorcycle-kx250-kx250-m1-2003-gear-change-mechanism/o/m3816sch292206[/url]) ([url]http://www.bikebandit.com/houseofmotorcycles/kawasaki-motorcycle-kx250-kx250-m1-2003-gear-change-drum-shift-forks/o/m3816sch293002[/url]) Make sure that the shifter is moving the shift drum.. You will see it when you have the clutch cover off. and try to move the lever... You may have to move the rear wheel at the same time to get the gearbox to move.. Also look at the parts fiche on bikebandit for the clutch, that will show you the blow up of the clutch, to make sure you have the washers in the right spot. There is a thick washer that goes between the basket and the bearing in the case.. If you don't have that one in place, you could have a binding between parts in the clutch area. It'd probably make a considerable amount of noise too. I also have to ask why you put the old head gasket back in? That head gasket is not reusable. Once you torque the head, that head gasket is done. If you take the head back off, you need to replace it. From what I can see, it only goes on one way. Is it possible that you put the new one on upside down? If you aren't sure which way to install a new head gasket on that bike, ask a mechanic at your local Kawi shop to show you.. Although most of them come with a mark to show you which side goes up. That could account for your white smoke. If I was you, I'd pull the clutch back apart, and make 100% certain that all of the parts are installed and in the right order. At the least, take some pictures and post them here and we should be able to help you identify the proper order. There have been many times I've wanted to give it all up over something like this, but remember it's just a simple machine, if it's not working as expected, there's a reason. And there is someone on here that should be able to help you identify that problem. Don't let it beat you. [/QUOTE]

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