Clutch Issue, Friction Plate Questions

Discussion specific to the 1989 - 1994 (E Series) KDX200 model sold in the USA
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gfalcone1
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Clutch Issue, Friction Plate Questions

Post by gfalcone1 »

https://www.kawasaki.com/Parts/PartsDia ... /KDX200-E2

I'm new to the KDX world (let's face it, dirt bikes and most things mechanical for that matter) and I have a couple issues with a 1990 KDX200 E2.
I stall even with the clutch lever engaged, something I've read a lot about on this forum. I need to do some work on it this week and I figured I'd do some clutch work as well. My question is, how many friction/steel plates are there in the 1990 E2 model? From the parts diagram above it looks like there are only 3 of each plate and they don't alternate, they double up. I'd just open it to look at the current situation, but I don't trust it either way.

Also, I can't find a basket at the moment, and I'm guessing I should replace it. Is filing any grooves/notches in the basket a good idea for the time being?

I'm fairly handy so long as I have the youtube and forums like this!

Thanks!
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Re: Clutch Issue, Friction Plate Questions

Post by KDXGarage »

Welcome to kdxrider.net. Congratulations on the KDX200-E2.

Check this diagram for a more accurate count on the plates.

https://www.partzilla.com/catalog/kawas ... -e2/clutch

Apparently, there is 1 special metal plate, then 6 more metals and 7 fibers. Look on EBC or other sites to see how many plates they have. Also, they might deal with the single OEM metal plate differently. I am not sure.

Research pictures here and elsewhere for "notched basket" and "notched clutch basket".

Sadly, the Kawasaki site is not really the best site to look for a parts diagram. It was 15 years ago! :prayer: :supz: buykawasaki.com, R.I.P. :cry: :cry:
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gfalcone1
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Re: Clutch Issue, Friction Plate Questions

Post by gfalcone1 »

Thanks for such a quick response! I still think I'm confused about how to read the diagram in your link. I see the quantities on the right indicating 7 fiber, 6 metal but given the actual diagram, I wouldn't know how to install. In the diagram itself, it looks like Basket, special metal plate, Friction, Two metal, Friction, Metal, Friction for a total of 3 of each (not including the special one). Am I simply looking at a diagram wrong?

Thanks again
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Re: Clutch Issue, Friction Plate Questions

Post by KDXGarage »

OK, after looking at it again, there is one special fiber in addition to the special metal plate. There are 7 fibers and 6 metals, then the special metal, then the special fiber.

inner hub, fiber, metal, fiber, metal, fiber, metal, fiber, metal, fiber, metal, fiber, metal, fiber, special metal, special fiber
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Re: Clutch Issue, Friction Plate Questions

Post by KDXGarage »

They are not going to show every single plate in the diagram, I think. That would be almost as bad as showing all 36 spoke nipples. :-)
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Re: Clutch Issue, Friction Plate Questions

Post by gfalcone1 »

I thought that might be the case, but thanks again for the help!
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Re: Clutch Issue, Friction Plate Questions

Post by KDXGarage »

I wish they did, but that's just nerdy me talking. :mrgreen: :busted:
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