KDXRIDER.NET

Hi guys, I have taken my clutch cover off to measure the wear on my friction plates. I thought I had put the clutch back together exactly like I took it apart, but when I put the clutch cover back on, the clutch release rod on the clutch cover won't rotate! I have a service manual, and put the clutch back together like it says. Can anyone help?

Probably some of the better mechanics will respond but immediate question is did you rotate the lever to the rear before putting the cover back on?

Sorry, my bike is a 1999 KDX 200

so i just need to rotate the clutch release lever out before i put the clutch cover on?

sorry, i am kinda a newb when it comes to clutches

Yeah, just rotate the lever to the rear about 90* before slipping the cover in place. If that doesn't work, then most likely you missed something so go back and review the manual.

the cover will go on the bike but when i rotate it forward to attach the cable, it hits the clutch pusher

Does that make sense?

Deleted wrong info

Sounds like you have something assembled wrong. Go back to the manual would be my suggestion.

I think i got it figured out, i had a few washers in the wrong place, and when i put them where the manual said, it all fit together. Thanks for the help and sorry to waste your time

Never a waste of time to try and help. In my recent overhaul I had to split the cases a second time just to check I hadn’t done something wrong. Can be frustrating.
Good luck with the bike.

No waste, just a problem solved. Congratulations.