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So I am putting together a 95 kdx 200 that I just bought. I tore it all down to do the top end and clean it up, and decided to replace the leaking clutch cover gasket.

I have the motor back on the bike and the clutch cable is hooked up but, when I squeeze the clutch cable the bike seems to stay in gear. Any ideas? I have the the cable tension set about as tight as i can. I didn't touch any of the clutch internals when I had the cover off. The bike was working fine when I tore it apart. Is this a clutch cable tension andjustment issue? Is it possible that the clutch release lever got turned around when I put it in?

thanks for the help

did you try this with the motor running or not?

the clutch needs to be spinning (engine running) in order to properly release
so if you tried it with the engine off that may be the problem right there

No, I haven't finished putting it all back together yet. Hopefully that is what it is. Thanks for the help.

There is a thick washer that sits inside the clutch basket. You have to be sure that it doesn't fall out of place when putting the clutch back onto the transmission input shaft. If it falls down between the plates and the basket, then you won't be able to get your clutch to release. Pop the clutch hub back out, get that washer positioned on the input shaft, reassemble, and you should be good to go.

dfeckel wrote:There is a thick washer that sits inside the clutch basket. You have to be sure that it doesn't fall out of place when putting the clutch back onto the transmission input shaft. If it falls down between the plates and the basket, then you won't be able to get your clutch to release. Pop the clutch hub back out, get that washer positioned on the input shaft, reassemble, and you should be good to go.

+1

I got the rest of the bike put back together this morning, fired it up and the clutch worked great. I guess it was due to not having the engine running. Thanks for the help, I'm glad it wasn't something more complicated. I just want to ride.