Clutch issue after rebuilt

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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KrispyKDX
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Clutch issue after rebuilt

Post by KrispyKDX »

Hello all,
Complete rebuild done on bottom and top end. Engine runs great and I can’t wait to go ride!
I have one issue with the clutch though. I did not replace anything on that clutch and was expecting everything to work as it was when I would put it back together but it is not!
I felt some resistance in the arm lever when I hooked the cable to it and I also felt some resistance on the first lever action but after that single action the hand lever became loose. It is only coming back because of the spring on the arm lever. It is like nothing is happening inside that cover.
Here are some pictures of how I did put it back together. Let me know what you think.
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SS109
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Re: Clutch issue after rebuilt

Post by SS109 »

Something was assembled incorrectly. Did you install the conical washer in the correct location and orientation?
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Re: Clutch issue after rebuilt

Post by KrispyKDX »

Thanks. The conical washer was installed right before the center nut and pointing out.
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Re: Clutch issue after rebuilt

Post by KrispyKDX »

Looking at my pictures I notice the marks on the clutch hub. Not linked to my problem but I am just curious on what did happen to make these marks!?! The inside of the cover shows no marks.
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Re: Clutch issue after rebuilt

Post by DonnyV »

Make sure when you put the clutch cover on the actuator is pointed towards the rear of the bike.
KrispyKDX
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Re: Clutch issue after rebuilt

Post by KrispyKDX »

I installed it exactly like shown in the picture. I had the right side of the bike in front of me. I did flip the cover 180 degrees and it went on like that. That makes the actuator pointing the rear once installed. You can see a picture of what it looks once hooked to the cable. Thanks again for the help.
As soon as I get some time I will uninstall the whole clutch and picture everything to show how I did it.
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Re: Clutch issue after rebuilt

Post by KDXGarage »

Check some other clutch parts on eBay pictures, as I think someone mentioned they were not exactly sanded to a high luster from the factory.
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Re: Clutch issue after rebuilt

Post by SS109 »

I wouldn't worry about the end of the clutch hub. If you notice, all the marks go in the same direction so it is not something caused by running the engine. It is from the manufacturing process or someone dragged it across something when it was out of the bike. Either way, no worries.
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Re: Clutch issue after rebuilt

Post by Laurenz_KDX200 »

Dont worry, my clutch has the same... i was already wondering too. It has to be from the factory process.
KrispyKDX
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Re: Clutch issue after rebuilt

Post by KrispyKDX »

Update on this issue: I did uninstall the whole clutch, took a picture of every step. It was right according the manual. I did reinstall it but this time using a method shown on a YouTube video where you assemble the whole clutch in the clutch basket before inserting it onto the shaft (but the position of every parts remained the same) and it is now working! I even looked at the pictures a couple of times to make sure everything was in the right order…I have a preference when I understand how I fixed things but I guess I’ll just move on. 🙂
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Re: Clutch issue after rebuilt

Post by SS109 »

Glad to hear you got it working. Now, go ride!
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Re: Clutch issue after rebuilt

Post by KrispyKDX »

Not yet! Haha I am still waiting for the carb jet block o’ring which I thought was what I had ordered from the parts list but…failed! This part is not shown in the part diagram from Kawa so I ordered it a couple of weeks ago. And yes since I am in Canada I had to order it from the us and now I am waiting! Should be here by the end of the week. This rebuild is taking me forever with the limited time I have but I have to say I like wrenching and taking good care of things. Next step will be to try to jet this thing. Only then I’ll go ride! Glad my KLX is not sold yet! 🙂
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Re: Clutch issue after rebuilt

Post by SS109 »

I don't understand why most parts places don't show the jet block gasket or even offer it for sale. Totally baffling. Well, hope it arrives soon!
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Re: Clutch issue after rebuilt

Post by KrispyKDX »

Hello all. I finalized the bike over the weekend and I want to check something with you guys. I adjusted the clutch cable to have just a slight slack but I noticed quite a lot of drag from that clutch. In gear, I am not able to freely push forward the bike with the clutch lever pulled. I compared with a couple of other bikes I have home and I can move these in the same situation… maybe normal? Note that I did not ride the bike yet. I might try it over the next weekend to see how it goes unless you guys tell me it’s absolutely not normal.
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Re: Clutch issue after rebuilt

Post by SS109 »

KDX's are known for not being the easiest to push while in gear. However, if you have a notched clutch basket it will make it noticeably worse.
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Re: Clutch issue after rebuilt

Post by KDXGarage »

I have KX's, KDX's and a YZ. All are tough to push with the clutch in. I put it in neutral to push it around.
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To post pictures from a device: viewtopic.php?f=88&t=24128
KrispyKDX
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Re: Clutch issue after rebuilt

Post by KrispyKDX »

Ok guys I was able to go for a ride and I confirm the clutch works but it did stall the first time I’ve put it in gear. I got it rolling and then came to a stop and no stall…worked good after that. Now I was able to find a new problem. Yeah! Rock on! I’ll start a separate thread to keep things clean.
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Re: Clutch issue after rebuilt

Post by tucker »

I suspect your basket wasn't fully seated or the pack was loose. It can happen if you install the plates on the bike rather than the pack off the bike.
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