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I replaced my plates and springs last season and ever since I have done so I hear a squealing while the engine is revving at high rpms and letting out the clutch slowly. Sounds like it is slipping or grinding. I've gone over the schematics and everything looks to be in order. I just recently replace the friction plates again and put some less stiff springs in it because I also had a really hard lever pull.

1991 kdx200

Any clue? Sorry for the lack of information this is all I know.

Cheers,
Ethan

Are you running the correct ratio gearbox oil ?

Check the oil level as it may be too low. ?

Clutch bearing excessive wear ?

Soak the plates before installing them?

I am running bel ray 75w. I recently rebuilt the bike a couple years ago, Whole engine. I noticed that the clutch basket will need to be replaced end of this year as there is a little bit of grooving starting to form but nothing to major, still is pretty smooth. I am wondering, maybe I am answering my own question. Could the clutch bolt that bolts down the basket be to tight? And the washer below the basket is rubbing which is causing a squeal? I soaked the plates ,yes.

My friend once had a ktm 450 exc that did a similar thing....if you pulled away quickly there would be an awful noise coming from the gearbox ( similar to your front brake pads howling when glazed over ) it turned out to be a worn clutch & not much oil in the motor !

pull the basket out and file down the grooves the plates could be getting stuck on them

You mentioned the washer behind the clutch basket. That washer should be a thrust washer, it's possible it is worn from low oil or just years of wear.