In need of #14032 Inner clutch side cover

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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bufftester
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Re: In need of #14032 Inner clutch side cover

Post by bufftester »

The spring for your shift mechanism is not engaged properly.
To keep the output shaft from spinning you can either block the rear wheel by using something through the spokes (not very good) or using an impact wrench (I have a Harbor Freight one that I bought specifically for this task, it was like 20$ years ago and only gets used a couple times a year but works like a champ). Put some penetrating oil and a little heat on it and give yours another try.
kaidoooo1987
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Re: In need of #14032 Inner clutch side cover

Post by kaidoooo1987 »

I hit the Clutch Hub nut with some chain lube I had, first attempted it with my impact before applying heat after; same result. I checked the manual to make sure it is only supposed to be 65 ft/lbs., yet it seems to be on VERY tight. I'm fairly confident that it has never been removed (I may be wrong). I started improvising a bit and found a unique way to keep the output end of the clutch positioned. Im going to let the oil work for a bit, then hit it with a torch and hope I can crack that stubborn Hub nut once and for all with my ratchet. I also wanted to post this picture and verify that the bike is indeed in neutral. Can you tell by where the shift mechanism meets the turret?? I would imagine the teeth would be more compressed if it were engaged in a gear. Thanks again for any input....I'll get this bike running sooner or later. :?
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bufftester
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Re: In need of #14032 Inner clutch side cover

Post by bufftester »

Neutral is the small indent above the pin, looks like you're already there. Make sure you get that shift pawl spring installed correctly, one leg goes on each side of the pin.
Mechdziner714
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Re: In need of #14032 Inner clutch side cover

Post by Mechdziner714 »

Impact is the way to go, if not get the motion pro gear jammer (15$)
kaidoooo1987
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Re: In need of #14032 Inner clutch side cover

Post by kaidoooo1987 »

Ok, i got the clutch hub nut off and replacedthe clutch. Now, the kickstart spring keeps coming disengaged as i install the side cover. Is there a particular way the spring needs to be wound??
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Re: In need of #14032 Inner clutch side cover

Post by Slick_Nick »

kaidoooo1987 wrote: 12:29 pm Feb 09 2023 Ok, i got the clutch hub nut off and replacedthe clutch. Now, the kickstart spring keeps coming disengaged as i install the side cover. Is there a particular way the spring needs to be wound??
Yes, it will stay in place if it’s wound properly.
'00 KDX 220R
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bufftester
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Re: In need of #14032 Inner clutch side cover

Post by bufftester »

Its very clearly detailed in the service manual. You need to verify that the detent pawl is located to the shaft correctly prior to installation.
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