Clutch not disengaging when in gear with clutch in

Discussion specific to the 1989 - 1994 (E Series) KDX200 model sold in the USA
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Jacobvw
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Clutch not disengaging when in gear with clutch in

Post by Jacobvw »

I bought new clutch plates, and springs. The clutch cable isnt getting caught up on anything. I have a 1989 kdx 200
Last edited by Jacobvw on 02:50 pm May 03 2021, edited 1 time in total.
Jacobvw
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Re: Clutch not disengaging when in gear with clutch in

Post by Jacobvw »

Any help would be appreciated.
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Re: Clutch not disengaging when in gear with clutch in

Post by KDXGarage »

Welcome to kdxrider.net.

Is this with the engine running or not?

Which brand parts did you use?
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Molly's 70
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Re: Clutch not disengaging when in gear with clutch in

Post by Molly's 70 »

Did you replace the clutch cable also?
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Re: Clutch not disengaging when in gear with clutch in

Post by Slick_Nick »

Clutch basket is probably notched. How bad was it when you put the new plates in? Doesn't take much to make the plates bind.
'00 KDX 220R
Jacobvw
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Re: Clutch not disengaging when in gear with clutch in

Post by Jacobvw »

Ok the backer wasn’t too bad I could barely feel them with my finger
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Re: Clutch not disengaging when in gear with clutch in

Post by Jacobvw »

The clutch plates i put in are ebc clutch plays and spring and I didn’t get a new cable but it’s not getting stuck up. And it when is when it’s off and in gear with the clutch pulled in it won’t roll and it stalls when it’s on.
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Re: Clutch not disengaging when in gear with clutch in

Post by bufftester »

With the engine off and in gear pulling the clutch in isn't going to make it easier to push, just the way these clutches are. If its stalling with the engine running then what did you torque the basket bolts too? Did you measure the EBC springs, there is lots of history of EBC springs not working on KDX clutches. If you have the original OEM ones you can try dropping them back in and see if that helps.
Jacobvw
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Re: Clutch not disengaging when in gear with clutch in

Post by Jacobvw »

Ok thanks I’ll try this
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Re: Clutch not disengaging when in gear with clutch in

Post by Jacobvw »

Hey thanks. This work the enc spring we’re just a bit. Offer and somehow made a big difference. Went on a ride and did some hillclimbs. thanks again for the help
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Re: Clutch not disengaging when in gear with clutch in

Post by sarrant »

Just put an EBC clutch in my '02 220 . Confirmed that the EBC heavy duty springs can coil bind in that application. Used stock springs.
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Re: Clutch not disengaging when in gear with clutch in

Post by KDXGarage »

I am glad you got it resolved.

Please do not post the same question in more than one thread / subforum.
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