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Hello! I have a 2002 kdx200 that has had this problem since the day AFTER I bought it. The clutch simply won’t engage. I pull the lever and it try’s to separate the plates but it only stretches the cable, tried adjusting the cable. Nope, bought new cable and adjusted it. Nope. Pull off the cover to reveal a worn basket, ok new basket, plates, and actuator rod… still won’t work, I’ve rebuilt the clutch 3 times now and torqued everything to spec and it still won’t work, bike runs and rides fine if you get a running start and shift without the clutch so I just have no idea on what it could be. It’s got to be something incredibly small. Any help at all helps. Thank y’all

Did you try removing the washer under the little operating rod or adding one? Technically, that is considered an adjustment point.

So, technically, the clutch won't "disengage". Have you checked your clutch springs free length?, Are you torquing to the service manual spec? Did the clutch work for the PO? What work was done after that point? It sounds like either the springs are bad, or they are over torqued, or both. With the clutch cover off, but the clutch cable still installed does the lever work normally rotating the actuator? Was the clutch stack up (to include the washers behind and inside the basket) correct? Some pics would be helpful

If everything checks out as new or in spec, then is the clutch pack being pushed out far enough? Getting the rear wheel off the ground may help check for free wheel.

bufftester wrote: 03:24 pm Mar 09 2022 So, technically, the clutch won't "disengage". Have you checked your clutch springs free length?, Are you torquing to the service manual spec? Did the clutch work for the PO? What work was done after that point? It sounds like either the springs are bad, or they are over torqued, or both. With the clutch cover off, but the clutch cable still installed does the lever work normally rotating the actuator? Was the clutch stack up (to include the washers behind and inside the basket) correct? Some pics would be helpful

It has brand new springs as well, I’m getting ready to tear into it so I’ll take some pics along the way

Here are some pics

They’re not new OEM springs. You have to check the free length like bufftester mentioned. If they’re not between 38.7 and 37.2 mm then that’s the problem.

John_S wrote: 07:00 pm Mar 10 2022 They’re not new OEM springs. You have to check the free length like bufftester mentioned. If they’re not between 38.7 and 37.2 mm then that’s the problem.

They are 39-40mm they’re heavy duty springs, it’s got a heavy duty clutch made by Barnett

I’ve gone over everything and this should be right except for torque specs, I have no idea what to torque the heavy duty springs down to, I guess I’ll try stock first just gotta wait for my buddy to get off work since he’s the one with the in lbs torque wrench

Hello everyone, recently my 2002 kdx200 has been having clutch problems and I’ve finally reached the point where I’m in the ballpark to solving it. Before I would squeeze the clutch lever and the plates wouldn’t budge and the cable would simply stretch, but after much time and difficulty everything is now working… except the disengagement of the clutch. I can now pull the lever, the push rod finally pushes and I can hear the plates moving except the clutch isn’t disengaging. I’ve messed with the cable trying to adjust it to no avail so now I don’t have a clue. Everything is torqued to spec. Any and all help is very much appreciated

Aftermarket clutch springs on the KDX are notorious for not working. lots of threads here and elsewhere documenting.

bufftester wrote: 12:20 am Mar 11 2022 Aftermarket clutch springs on the KDX are notorious for not working. lots of threads here and elsewhere documenting.

Yup! I 100% agree.

M A N G O wrote: 11:19 pm Mar 10 2022 Hello everyone, recently my 2002 kdx200 has been having clutch problems and I’ve finally reached the point where I’m in the ballpark to solving it. Before I would squeeze the clutch lever and the plates wouldn’t budge and the cable would simply stretch, but after much time and difficulty everything is now working… except the disengagement of the clutch. I can now pull the lever, the push rod finally pushes and I can hear the plates moving except the clutch isn’t disengaging. I’ve messed with the cable trying to adjust it to no avail so now I don’t have a clue. Everything is torqued to spec. Any and all help is very much appreciated

I'm going to combine this post with the discussion you already have going on about this very issue. This way all info is in one place.

Keep in mind that the KDX clutch drags a lot. As in if you pull the lever in you may still not be able to push the bike while in gear. Put it in neutral, start it, then with the clutch pulled in drop it in gear, you will know quickly if its working.

Throw the old oem springs back on to see if anything changes?