Clutch Woes

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dc2012
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Clutch Woes

Post by dc2012 » 08:53 am Sep 27 2019

So I haven't had this bike long. I have now lowered it with links, replaced the fork boots, re-covered the seat, done some carb work, and replaced all the fluids. It's a 98 KDX200. It's running great except one thing. When the engine is off and I pull the clutch, the bike doesn't freewheel when it's in gear. It acts like the clutch doesn't work. When the engine is running and I'm starting off first, I have to let the clutch 3/4 the way out before it starts to grab at all. So on one hand my clutch is acting like it doesn't work and on the other hand it's acting like It's overly engaged. I'm not sure if this is a fluid thing or not because I habitually keep it in neutral when pushing it around so I never noticed if this is a problem it had previously or if I created it. Clutches are not something I'm much familiar with so guidance would be great. Thanks everyone.

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Re: Clutch Woes

Post by Molly's 70 » 01:15 pm Sep 27 2019

Check for grooves in your clutch basket.
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Re: Clutch Woes

Post by bufftester » 04:44 pm Sep 27 2019

Completely normal for a KDX. Some folks running ATF report that it gets a bit better with the thinner oil. The 220s are the same way, pull the clutch and its a bear to push around if not in N.

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Re: Clutch Woes

Post by KDXGarage » 04:48 pm Sep 27 2019

I have had a few off-road bikes. All of them don't move well with the engine off and clutch pulled in.

How much free play do you have at the lever gap in the perch?

Since it is 22 years old, the plates or basket may be worn. If you decide to take it apart to check, you may want to have a service manual and new OEM gasket handy.
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Re: Clutch Woes

Post by SS109 » 10:38 am Sep 28 2019

Sounds like a normal dirt bike IMO/IME. Even my buddy's new YZ250X is the same way.
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Re: Clutch Woes

Post by kdxsully » 06:11 pm Sep 28 2019

+1 mine does it. The oil sticks the plates together like glue.
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Re: Clutch Woes

Post by John_S » 07:51 pm Sep 28 2019

That's how I've always known dirtbikes (or street, atv) to act. It's like when someone push starts a bike they always do in neutral and then when up to speed, kick it into gear. If it was in first with the clutch in, they'd never get it going quick enough to bump start. My 220 has a new ProX basket and new Oem steels, frictions, and springs and I have to let the clutch out most of the way before it starts to move. I like it becuase it makes it easy to modulate slip with one finger. I believe what you're experiencing is normal but an inspection would be good insurance to see if anything is out of spec.

dc2012
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Re: Clutch Woes

Post by dc2012 » 05:08 pm Sep 30 2019

Man that's interesting. My CRF freewheels like a champ when I pull in the clutch, running or not. My other two bikes are hondas so maybe that's why it seems abnormal to me.

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Re: Clutch Woes

Post by bufftester » 05:13 pm Sep 30 2019

The Hondas use a different clutch arrangement where the clutch actuates opposite of the KDX. You note this by where the clutch cable enters the case (on the left for the CRF and a lot of the newer MX bikes), on the right attached to a lever arm on the KDX and most of your older enduro bikes. My RMX does the same thing, though not quite as bad.

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Re: Clutch Woes

Post by KDXGarage » 07:27 pm Sep 30 2019

I don't ride no junky Hondas!! :grin:
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