Frozen Clutch Issues! WTF?

Got questions? We got answers....
Post Reply
Ecarta
Member
Posts: 59
Joined: 11:17 am Feb 08 2022
Country: United States

Frozen Clutch Issues! WTF?

Post by Ecarta »

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!!!
Last edited by Ecarta on 01:20 pm Apr 23 2022, edited 1 time in total.
User avatar
Slick_Nick
Supporting Member
Posts: 1675
Joined: 10:06 pm Oct 22 2009
Country: Canada
Location: Calgary, Alberta
Contact:

Re: Frozen Clutch Issues! WTF?

Post by Slick_Nick »

Were those "aftermarket springs" EBC brand by chance? If so, that's your problem. They belong in the garbage.
'00 KDX 220R
Ecarta
Member
Posts: 59
Joined: 11:17 am Feb 08 2022
Country: United States

Re: Frozen Clutch Issues! WTF?

Post by Ecarta »

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.
User avatar
Slick_Nick
Supporting Member
Posts: 1675
Joined: 10:06 pm Oct 22 2009
Country: Canada
Location: Calgary, Alberta
Contact:

Re: Frozen Clutch Issues! WTF?

Post by Slick_Nick »

What do you mean your clutch “locks up”? Pull th clutch cover off and post a pic.
'00 KDX 220R
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: Frozen Clutch Issues! WTF?

Post by KDXGarage »

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?
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
Ecarta
Member
Posts: 59
Joined: 11:17 am Feb 08 2022
Country: United States

Re: Frozen Clutch Issues! WTF?

Post by Ecarta »

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.
Ecarta
Member
Posts: 59
Joined: 11:17 am Feb 08 2022
Country: United States

Re: Frozen Clutch Issues! WTF?

Post by Ecarta »

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.
Ecarta
Member
Posts: 59
Joined: 11:17 am Feb 08 2022
Country: United States

Re: Frozen Clutch Issues! WTF?

Post by Ecarta »

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
User avatar
Slick_Nick
Supporting Member
Posts: 1675
Joined: 10:06 pm Oct 22 2009
Country: Canada
Location: Calgary, Alberta
Contact:

Re: Frozen Clutch Issues! WTF?

Post by Slick_Nick »

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?
'00 KDX 220R
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: Frozen Clutch Issues! WTF?

Post by SS109 »

How notched is your clutch basket?
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
Ecarta
Member
Posts: 59
Joined: 11:17 am Feb 08 2022
Country: United States

Re: Frozen Clutch Issues! WTF?

Post by Ecarta »

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?!
Ecarta
Member
Posts: 59
Joined: 11:17 am Feb 08 2022
Country: United States

Re: Frozen Clutch Issues! WTF?

Post by Ecarta »

SS109 wrote: 01:37 am Apr 25 2022 How notched is your clutch basket?
Mildly but I then filed them down a bit
Ecarta
Member
Posts: 59
Joined: 11:17 am Feb 08 2022
Country: United States

Re: Frozen Clutch Issues! WTF?

Post by Ecarta »

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!
User avatar
Slick_Nick
Supporting Member
Posts: 1675
Joined: 10:06 pm Oct 22 2009
Country: Canada
Location: Calgary, Alberta
Contact:

Re: Frozen Clutch Issues! WTF?

Post by Slick_Nick »

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.
'00 KDX 220R
User avatar
Slick_Nick
Supporting Member
Posts: 1675
Joined: 10:06 pm Oct 22 2009
Country: Canada
Location: Calgary, Alberta
Contact:

Re: Frozen Clutch Issues! WTF?

Post by Slick_Nick »

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.
'00 KDX 220R
Ecarta
Member
Posts: 59
Joined: 11:17 am Feb 08 2022
Country: United States

Re: Frozen Clutch Issues! WTF?

Post by Ecarta »

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!
User avatar
KDXGarage
KDXRider.net
KDXRider.net
Posts: 14047
Joined: 06:45 am Nov 01 2004
Country: United States of America
Location: AL, USA
Contact:

Re: Frozen Clutch Issues! WTF?

Post by KDXGarage »

Good enough! Enjoy the KDX's.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
Ecarta
Member
Posts: 59
Joined: 11:17 am Feb 08 2022
Country: United States

Re: Frozen Clutch Issues! WTF?

Post by Ecarta »

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