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Just got my new clutch kit. I tried to slide the friction plates on, and it won't go. The ones I took off were difficult to get off too. I broke two trying to get it off. Should it be this hard?

don t forget to soak them before putting them on.

Is it difficult getting them on the hub or in the basket?

In the basket. I got them all in there after filing the fingers a bit. But now the clutch won't engage. I don't have a torque wrench right now, so I didn't torque the clutch springs down to spec. Could the clutch springs being too loose or tight keep it from engaging?

Also, the clutch lever won't pull all the way in, if that helps any.

Are any of the clutch fingers bent or distorted?

And yes, something is wrong if you are having to try that hard to get new ones on or breaking the old ones getting them off.

Also, my manual mentions a coned disc spring the goes between the top two friction plates. But, when I took the clutch off, I never saw one. Also, is there supposed to be a washer between the "clutch pusher arm" and the little bearing thing it slips in to? I know there a small shim like washer, but is there a bigger on?

taking the plates off and reinstalling them shouldn't be an issue at all unless severely warped like Ted mentioned. the clutch spring bolts are gonna be tightened all the way down like any other bolt, but yes you do wanna check on proper torque, not that a little too much won't hurt just try not to strip the threads. you're engagement issue sounds like something on the pushrod assembly that wasn't installed correctly, look on bike bandit.com for a parts diagram to see how everything lines up and what goes where

10-4. I checked and it looks like I'm missing a washer that goes between the inner hub and the clutch basket. But could that make it not engage?

superman27e wrote:10-4. I checked and it looks like I'm missing a washer that goes between the inner hub and the clutch basket. But could that make it not engage?

Without that washer you are sandwiching the inner hub and basket together. That washer spaces them apart so the can rotate independent of each other.

Thanks for the info, guys! It was because the washer wasn't between the inner hub and basket. I found stuck together with the washer that goes behind the basket. :p Now, time to ride in this rain!

Spoke too soon. Now it's slipping worse than before. Any ideas?

What kind of oil did you use?

Regular non synthetic 10-40. I've always used it

superman27e wrote:Just got my new clutch kit. I tried to slide the friction plates on, and it won't go. The ones I took off were difficult to get off too. I broke two trying to get it off. Should it be this hard?

This has to be related to your problem. I have never had frictions plates that were difficult to get on or off.

You think that'd make it slip, though?

Would a clutch basket from a 99 200 fit on my 99 220?

they're the same.

I was just taking it off again to check everything out and noticed that the inner hub is spinning freely with almost no resistance at all, other than it spinning the steel plates. Is it supposed to move that freely?

If your transmission is in neutral it would rotate pretty easily. If your transmission is in gear it shouldnt rotate.