Broke a clutch friction plate - locked up motor with mystery piece of aluminum

[MotoFo]

Doing hillclimbs at the local riding area. Clutching the heck out of the motor when it locked up. I got home, drained the oil and a sizable piece of aluminum came out of the drain and no more lock-up. Removing the clutch I found a broken clutch plate. The basked looks fine - a little filing in order. But I can't see where this piece of aluminum came from. Any have any ideas?











EDITED ON 04-06-2025 by KDXGarage: See pics in my post below. My browser shows the hosting site as not secure.

[kdxdazz]

I can't view the photos

[kdxdazz]

I see it now, do all the pieces of your broken clutch plate line up perfectly or has that small piece broken off then become unrecognisable as it got crushed

[MotoFo]

All the pieces of the clutch plate are accounted for. It makes me nervous that I can't find where this piece came from. I guess I'll put a new clutch in it and hope for the best.

[bufftester]

There is a bit of web behind the kick start gear that could be suspect

[Chuck78]

The pictures aren't showing up for me. Where are they hosted? Perhaps there's a bandwidth restriction imposed by the hosting site.

I'm guessing these were probably Tusk or other aftermarket clutch discs that shattered? I've never heard of one self destructing before. Wow.

[KDXGarage]

The pictures are on a site that is not secure from what I could tell.

You have blue goop pieces in the engine. There is one on the cover and one behind a flat attached piece (pic 3, 1:00 from the shaft, about an inch away). I don't know if the blue goop caused the issue, but pieces floating around probably is not a good thing.

Did the piece come from 10:30 from the shaft, about 2 inches away? From the pics, that is my best guess.

KDX200_Clutch_Issue-1.jpg (673.48 KiB) Viewed 3539 times

KDX200_Clutch_Issue-2.jpg (586.15 KiB) Viewed 3539 times

KDX200_Clutch_Issue-3.jpg (535.25 KiB) Viewed 3539 times

KDX200_Clutch_Issue-4.jpg (537.27 KiB) Viewed 3539 times

KDX200_Clutch_Issue-5.jpg (685.06 KiB) Viewed 3539 times

[MotoFo]

The blue goop was used in lieu of a gasket. I purchased the bike as such. No idea what brand the clutch plates were. I'll clean it all up, use a gasket, install a new clutch and hope for the best as I don't see where the piece of aluminum came from. The clutch was really getting worked on all the hill climbs. Breaking a clutch plate is a first for me. Also, I host the site I put the photos on. Does it need to be a secure site? I'm only semi tech savvy.

[KDXGarage]

You might want to take off the inner clutch cover to better investigate where the chunk may have come from.

I think the site does need to be secure. Not sure. I couldn't see them without going in and opening each in a new tab. I saved them and put them in my post.

[Chuck78]

I'd imagine that chunks of the silicone type sealer used in lieu of a proper gasket had gone astray from the excessive amount used, and a chunk got lodged between clutch plates, which caused the backing plate to shatter and go flying through the clutchcase, getting caught between the clutch basket fingers and a crankcase rib, shearing off the rib...