clutch "jutter spring"

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
Post Reply
tucker
Supporting Member I
Supporting Member I
Posts: 68
Joined: 03:30 am Oct 15 2018
Country: New Zealand
Location: New Zealand

clutch "jutter spring"

Post by tucker »

I've been trying to figure out which way the spacer needs to go. given it is a cone shape and oriented up one way. I searched the forum and see this referred to as the jutter spring but couldnt get a definitive answer nor from youtube videos.

Which way should this face when I am rebuilding the clutch? Problem was I couldn't have it horiztontal so things moved around when i pulled the clutch pack out.

Cheers
User avatar
ericr
Gold Member
Gold Member
Posts: 246
Joined: 06:57 pm Nov 06 2017
Country: USA
Location: Gig Harbor, WA

Re: clutch "jutter spring"

Post by ericr »

I think you're talking about what's called the "coned disc spring" in the manual. It's installed with the ID higher than the OD.
coned disk spring.JPG
coned disk spring.JPG (24.35 KiB) Viewed 3403 times
'02 KDX 200, '02 KDX 220 - My restoration thread
tucker
Supporting Member I
Supporting Member I
Posts: 68
Joined: 03:30 am Oct 15 2018
Country: New Zealand
Location: New Zealand

Re: clutch "jutter spring"

Post by tucker »

Yep i think that is it but it still doesn't make sense to me.

(a) does the spring and spring seat go into the basket before the plates?
(b) from your explanation, the cone would if on a flat table would be pointing up?

sorry if these are dumb questions it just isnt clean to me from manual
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: clutch "jutter spring"

Post by SS109 »

The judder spring should go at the very top of the clutch pack with the "cone" of it facing outward (towards the pressure plate) and the second flat spring goes on top of it.
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
tucker
Supporting Member I
Supporting Member I
Posts: 68
Joined: 03:30 am Oct 15 2018
Country: New Zealand
Location: New Zealand

Re: clutch "jutter spring"

Post by tucker »

Thanks - "top" of the clutch pack being closest to the pressure plate (so last to go on?)
User avatar
ericr
Gold Member
Gold Member
Posts: 246
Joined: 06:57 pm Nov 06 2017
Country: USA
Location: Gig Harbor, WA

Re: clutch "jutter spring"

Post by ericr »

tucker wrote: 08:28 pm Apr 14 2020 Thanks - "top" of the clutch pack being closest to the pressure plate (so last to go on?)
That's correct, last to go on, pointed up, then the flat washer. BTW, there's no such thing as dumb questions here. We all started from the same point with these bikes. Good luck!
'02 KDX 200, '02 KDX 220 - My restoration thread
tucker
Supporting Member I
Supporting Member I
Posts: 68
Joined: 03:30 am Oct 15 2018
Country: New Zealand
Location: New Zealand

Re: clutch "jutter spring"

Post by tucker »

I watched this video here - see about 1:10 in. Does this mean he has put them on wrong?

User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: clutch "jutter spring"

Post by SS109 »

He put them on in the correct order. He just never removed the flat one from the pressure plate.
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
User avatar
Kdxfan4130
Supporting Member II
Supporting Member II
Posts: 116
Joined: 09:24 pm May 30 2019
Country: Usa

Re: clutch "jutter spring"

Post by Kdxfan4130 »

Interesting you never read about toasted clutches on the kdx200/220. Big bore 350 kit on a klx250s was a different story.
Nice vid thanks for posting
Restore rather than replace
DonnyV
Supporting Member I
Supporting Member I
Posts: 68
Joined: 05:28 pm Nov 10 2020
Country: United States

Re: clutch "jutter spring"

Post by DonnyV »

I know this is an older post but I have a question about something in the video in this post, @ 9 min mark the guy is talking about the spring washer and the nut, he says it goes on with the higher outside facing the nut, my book on 5-13 it shows it the opposite of that, which is right, I'm guessing the book because the guy didn't change the top fiction plate like the book says either. I'm currently about to get to this on my rebuild and just want confirm, thanks
03 220 w/fmf rev, RB head mod
User avatar
bufftester
Platinum Member
Platinum Member
Posts: 3455
Joined: 06:03 pm Oct 31 2012
Country: USA
Location: University Place, WA

Re: clutch "jutter spring"

Post by bufftester »

The clutch hub nut washer goes on with the convex side facing out.
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: clutch "jutter spring"

Post by SS109 »

Hmm, I've always installed the washer with the convex side in IIRC. That's what the service manual shows is the correct way. Here is a screen shot of it...

conical washer.jpg
conical washer.jpg (37.44 KiB) Viewed 1634 times
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
DonnyV
Supporting Member I
Supporting Member I
Posts: 68
Joined: 05:28 pm Nov 10 2020
Country: United States

Re: clutch "jutter spring"

Post by DonnyV »

Thanks for confirming, to me the manual shows convex towards the nut "out" like bufftester says, interesting that people see it different ways. Looking at the clutch hub where that washer would sit if it was convex in it would rub on the inside by the shaft splines because the clutch hub has a slight concave there. Sorry I should have started a new topic with this.
03 220 w/fmf rev, RB head mod
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Re: clutch "jutter spring"

Post by SS109 »

DonnyV wrote: 04:43 pm Feb 04 2022 Thanks for confirming, to me the manual shows convex towards the nut "out" like bufftester says, interesting that people see it different ways. Looking at the clutch hub where that washer would sit if it was convex in it would rub on the inside by the shaft splines because the clutch hub has a slight concave there. Sorry I should have started a new topic with this.
Ugh. Yeah, I messed up my terminology. Convex vs concave. :kick:
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
Post Reply