HELP!! Where did this washer come from?! Bottom end.

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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KingDaddyX
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HELP!! Where did this washer come from?! Bottom end.

Post by KingDaddyX »

When I pulled my clutch cover this washer/shim/spacer was tacoed over wrapped around my clutch arm.
ID is 18-19mm, OD 21.5-22.5 (because it’s oblong now), thickness is 1.01mm best I can measure.
I have no clue where it goes. The bike is running fine, I was just going to install an EBC clutch/ new part# OE springs.
The old clutch wasn’t bad, the springs in the 96 are weaker I’ve heard so that’s why I decided to replace them. I got the clutch kit at dealer cost so I was just taking advantage of a deal, again, no known issues. I haven’t had the bottom end apart in maybe 80-100 hours, hopefully no major damage was done and it found its place quickly. I have even done like 6 hare scrambles on the bike since then. Nothing unusual in the oil to speak of. I was hoping to have it back together quickly since riding season is going by fast so this really blows.

Thanks in advance!
KingDaddyX
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Posts: 29
Joined: 12:00 am May 11 2025
Country: United States
Location: Central alabama

Re: HELP!! Where did this washer come from?! Bottom end.

Post by KingDaddyX »

Looks like it came off the kickstarter shaft. Probably just slid off unnoticed as I was trying to line everything up and get the cover on, it’s been years but I think it didn’t go on smoothly the first try so that makes sense.

Think I can get away with just leaving it off and replacing it next time I’m in there? It’s not like the shaft is spinning with the motor. I’ll have .53mm more play on the gear teeth mating surface and my cover may wear. I may have to use 2 washers next time haha. Unless I’m missing another good reason?
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SpruceItUp
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Re: HELP!! Where did this washer come from?! Bottom end.

Post by SpruceItUp »

Ah, it seems you figured it out! I am not sure if leaving it out will cause any issues or not, but if it was me I would order one up and replace it while you've got it apart. Now if you're planning on riding tomorrow or something like that I'd say to h*** with it and just run it until I get the part.
92 KDX200
04 CRF450R
05 CR125R
~Don't mind me, I can be a little slow :lol: :lol:
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