Clutch

[Aircooled22]

Hi guys, I have taken my clutch cover off to measure the wear on my friction plates. I thought I had put the clutch back together exactly like I took it apart, but when I put the clutch cover back on, the clutch release rod on the clutch cover won't rotate! I have a service manual, and put the clutch back together like it says. Can anyone help?

[doakley]

Probably some of the better mechanics will respond but immediate question is did you rotate the lever to the rear before putting the cover back on?

[Aircooled22]

Sorry, my bike is a 1999 KDX 200

[Aircooled22]

so i just need to rotate the clutch release lever out before i put the clutch cover on?

[Aircooled22]

sorry, i am kinda a newb when it comes to clutches

[doakley]

Yeah, just rotate the lever to the rear about 90* before slipping the cover in place. If that doesn't work, then most likely you missed something so go back and review the manual.

[Aircooled22]

the cover will go on the bike but when i rotate it forward to attach the cable, it hits the clutch pusher

[Aircooled22]

Does that make sense?

[Kdxfan4130]

Deleted wrong info

[doakley]

Sounds like you have something assembled wrong. Go back to the manual would be my suggestion.

[Aircooled22]

I think i got it figured out, i had a few washers in the wrong place, and when i put them where the manual said, it all fit together. Thanks for the help and sorry to waste your time

[doakley]

Never a waste of time to try and help. In my recent overhaul I had to split the cases a second time just to check I hadn’t done something wrong. Can be frustrating.
Good luck with the bike.

[KDXGarage]

No waste, just a problem solved. Congratulations.