KDXRIDER.NET

Help, clutch won’t engage….
I just wrote out a long post and it tells me I’m not logged in when I clearly am….

Here I go writing it all over again…

I have a 2006 KDX200….. I have owned this bike fir 6 years snd never had a problem with it… I just hauled it 250 miles last night to bring it yo a new trail system… before I left I installed a new shorty clutch lever… it had a good pull and felt fine so I didn’t test ride it…. I just went to ride it and the clutch won’t engage… tried 1st and 2nd… nothing… removed the clutch lever completely and still nothing…. Bike ran fine last time I rode it…. Before I throw in the towel and drive all the way home I thought I’d post here to see if anyone thinks it’s some thing simple…. I’m in Patten Maine and the closest mechanic in an hour north in the wrong direction….. what could it be? Thanks anxiously awaiting a reply

I would return your bike to the way it was & see what happens.

Removed the clutch lever completely…. And pushed the lever on top of the clutch cover all the way back… bike still won’t move

What I want to know is if pulling the clutch cable to far out could have caused this problem….. doesn’t make any sense… bike ran perfect last time I rode it…. Can a clutch just go completely fir no reason?

Most likely something simple and related to the work you did. I'd agree with putting it back like it was and trying. I'm "assuming" the clutch lever arm on top of the cover is in its normal position and rotates when you pull the hand lever?

Well I spoke to a mechanic…. He said I shouldn’t be able to move the lever on top of the clutch cover… which makes sense….. however I can move it back n forth easily… I took the clutch cover off….. boy the disengagement mechanism is weird…. But there’s nothing obviously wrong… I was hoping to see some clip or something laying in there… whatever is broken is deep in the motor…. I’m fucked… I can’t believe this bike choose this day to break with no indacation of this coming….. the one time I haul it long distance…… looks like I’m heading home

Does your lever still have a good pull feel? If you put it in 1st and try to roll it does it roll freely? Sounds like a transmission issue, just changing a lever shouldn't have caused any issues.

You can move the lever on top of the clutch cover back n forth with your finger…. Cable disconnected… you still have to put the bike in neutral for it to roll…

Does the clutch lever have the same resistance to it as it did with the one you replaced? If the clutch actuator can be easily moved by hand over it's arc then I would lean towards that you broke the clutch inner hub (part # 13086-1069), possibly, due to over tightening the clutch cable, and then pulling the lever, thus breaking it.

Sounds right…. I’m home now and will look into it… have you ever replaced this part? Do I have to unbolt all the clutch plates? Now I need a video of someone replacing this part…. Thanks

I see that part listed in the clutch section on babbits website however I can’t find it in the picture above the part # listing

I googled that part number and it brought up a dozen ad listings but not one of these ads shows a picture of the part ..

Sounds like maybe you do not have a service manual perhaps?

It’s fixed…. Apparently I disengaged the clutch to much and the top pressure plate moved out of its slot

Awesome!