KDXRIDER.NET

Hello everyone, my clutch locks up only at speed, whats going on?

After a rebuild, I installed my old clutch with new EBC springs because the existing springs were out of spec (about 35.2mm). But after reassembly, the clutch lever had immediate resistance like it was stuck.
I did 3 things to correct problem:
A. Soaked friction plates in motorcycle oil for 24 hours.
B. Removed new springs and reinstalled old ones.
C. Lightly filed down bumps on clutch basket fingers.

Next day reassembled clutch. And it worked smooth as butter! I was happy and went to bed!

But next day:
After 2 miles at 60 mph, clutch was stuck again. I was getting same resistance as previously stated. COINCIDENCE?
After a few minutes, magically, the clutch started working again...lol...?????

On way home did same thing..If I coast down to 20mph it magically works again. I repeated this 3 times pretty consistently.

What is going on?? Remember this is a previously working clutch. My buddy mechanic for 35 years has no idea what could be happening. HELP!!!

Were those "aftermarket springs" EBC brand by chance? If so, that's your problem. They belong in the garbage.

Slick_Nick wrote: 11:20 am Apr 23 2022 Were those "aftermarket springs" EBC brand by chance? If so, that's your problem. They belong in the garbage.

Originally I installed the new springs which were EBC. And clutch was locked up. But then I put old springs back in, clutched worked! UNTIL I Road at 60mph for 2 miles then locked up again! But magically works again after I slow down or stop for a bit.

What do you mean your clutch “locks up”? Pull th clutch cover off and post a pic.

Which oil?

Any chance you left out a washer or put it in the wrong order?

What was your technique on tightening the spring bolts?

Slick_Nick wrote: 05:07 pm Apr 23 2022 What do you mean your clutch “locks up”? Pull th clutch cover off and post a pic.

Locks up as in the lever is next to impossible to pull. And it will simply not work.

KDXGarage wrote: 08:47 pm Apr 23 2022 Which oil?

Any chance you left out a washer or put it in the wrong order?

What was your technique on tightening the spring bolts?

No I triple check the order I have disassembled and reassembled the clutch now about 10x so far. I did not tighten the clutch spring bolts all the way until they bottomed out. I set my torque wrench to 78 in/lbs and when it clickedbI stopped. Well short of bottoming out.

KDXGarage wrote: 08:47 pm Apr 23 2022 Which oil?

Any chance you left out a washer or put it in the wrong order?

What was your technique on tightening the spring bolts?

Oh btw.....BTW...used Valvoline 10W40 full synthetic

Post a photo. I have a feeling you’ve got something in upside down or backwards. You’re not using the stock judder springs are you?

How notched is your clutch basket?

Slick_Nick wrote: 09:26 am Apr 24 2022 Post a photo. I have a feeling you’ve got something in upside down or backwards. You’re not using the stock judder springs are you?

What's a judder spring?!

SS109 wrote: 01:37 am Apr 25 2022 How notched is your clutch basket?

Mildly but I then filed them down a bit

IDK what I did but clutch works fine now! I have 2 kdx200s.
I swapped the clutches and both work good

Thank you everyone for your input!

Ecarta wrote: 06:57 am Apr 26 2022

Slick_Nick wrote: 09:26 am Apr 24 2022 Post a photo. I have a feeling you’ve got something in upside down or backwards. You’re not using the stock judder springs are you?

What's a judder spring?!

Its the stock (I believe two) rings that dampen the vibrations in the clutch. They're not to be used with an aftermarket clutch kit.

Ecarta wrote: 07:02 am Apr 26 2022 IDK what I did but clutch works fine now! I have 2 kdx200s.
I swapped the clutches and both work good

Thank you everyone for your input!

I'm guessing something was in upside down and/or backwards, and on reassembly it went together properly. Seems very strange that one clutch just doesn't work in a specific bike.

Slick_Nick wrote: 08:08 am Apr 26 2022

Ecarta wrote: 07:02 am Apr 26 2022 IDK what I did but clutch works fine now! I have 2 kdx200s.
I swapped the clutches and both work good

Thank you everyone for your input!

I'm guessing something was in upside down and/or backwards, and on reassembly it went together properly. Seems very strange that one clutch just doesn't work in a specific bike.

Yeah must have been something like that, oh well glad it's working now!

Good enough! Enjoy the KDX's.

KDXGarage wrote: 10:15 pm Apr 26 2022 Good enough! Enjoy the KDX's.

Hell yeah!

Slick_Nick wrote: 08:07 am Apr 26 2022

Ecarta wrote: 06:57 am Apr 26 2022

Slick_Nick wrote: 09:26 am Apr 24 2022 Post a photo. I have a feeling you’ve got something in upside down or backwards. You’re not using the stock judder springs are you?

What's a judder spring?!

Its the stock (I believe two) rings that dampen the vibrations in the clutch. They're not to be used with an aftermarket clutch kit.

April 27, 2024

Dear Slick Nick,
2 years ago you gave me some clutch advice that I would like to touch base on......You mentioned that the concave and flat judder springs are not to be used with an aftermarket clutch kit. You sure that's correct? What's so different between oem and Tusk friction/steel plates? Aren't they there for a reason?

Getting ready to reassemble my clutch and wanna make sure I'm doing everything correctly.

Ecarta

Ecarta wrote: 05:37 pm Apr 27 2024

Slick_Nick wrote: 08:07 am Apr 26 2022

Ecarta wrote: 06:57 am Apr 26 2022

What's a judder spring?!

Its the stock (I believe two) rings that dampen the vibrations in the clutch. They're not to be used with an aftermarket clutch kit.

April 27, 2024

Dear Slick Nick,
2 years ago you gave me some clutch advice that I would like to touch base on......You mentioned that the concave and flat judder springs are not to be used with an aftermarket clutch kit. You sure that's correct? What's so different between oem and Tusk friction/steel plates? Aren't they there for a reason?

Getting ready to reassemble my clutch and wanna make sure I'm doing everything correctly.

Ecarta

That is correct.