Frozen Clutch Issues! WTF?
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Frozen Clutch Issues! WTF?
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!!!
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.
- Slick_Nick
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Re: Frozen Clutch Issues! WTF?
Were those "aftermarket springs" EBC brand by chance? If so, that's your problem. They belong in the garbage.
'00 KDX 220R
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Re: Frozen Clutch Issues! WTF?
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.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.
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Re: Frozen Clutch Issues! WTF?
What do you mean your clutch “locks up”? Pull th clutch cover off and post a pic.
'00 KDX 220R
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Re: Frozen Clutch Issues! WTF?
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?
Any chance you left out a washer or put it in the wrong order?
What was your technique on tightening the spring bolts?
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Re: Frozen Clutch Issues! WTF?
Locks up as in the lever is next to impossible to pull. And it will simply not work.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.
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Re: Frozen Clutch Issues! WTF?
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.
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Re: Frozen Clutch Issues! WTF?
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
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Re: Frozen Clutch Issues! WTF?
How notched is your clutch basket?
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AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
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Re: Frozen Clutch Issues! WTF?
What's a judder spring?!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?
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Re: Frozen Clutch Issues! WTF?
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 swapped the clutches and both work good
Thank you everyone for your input!
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Re: Frozen Clutch Issues! WTF?
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: ↑06:57 am Apr 26 2022What's a judder spring?!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?
'00 KDX 220R
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Re: Frozen Clutch Issues! WTF?
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
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Re: Frozen Clutch Issues! WTF?
Yeah must have been something like that, oh well glad it's working now!Slick_Nick wrote: ↑08:08 am Apr 26 2022I'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.
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Re: Frozen Clutch Issues! WTF?
Good enough! Enjoy the KDX's.
Thank you for participating on kdxrider.net.
To post pictures from a device: viewtopic.php?f=88&t=24128
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Re: Frozen Clutch Issues! WTF?
Slick_Nick wrote: ↑08:07 am Apr 26 2022Ecarta wrote: ↑06:57 am Apr 26 2022What's a judder spring?!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?
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
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Re: Frozen Clutch Issues! WTF?
That is correct.Ecarta wrote: ↑05:37 pm Apr 27 2024Slick_Nick wrote: ↑08:07 am Apr 26 2022
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
'00 KDX 220R