Hi everyone! Just picked up a 2000 KDX220R that has been sitting for a while. Last thing left to do is get this clutch replace. I watched all the videos that were recommended on this forum, but i can't seem to figure out why after assembling it, the clutch is near impoossible to pull in. took the cable out and tried to engage the clutch with a adjustable wrench and it won't budge. Any ideas?
Things i've done:
Soaks the frictions disks over night
There's a washer behind the basket, then a washer on the other side where the rest of the clucth assembly slide on.
I checked to make sure i have the flat ring and the judder ring placed correctly.
I made sure when the 2 big piece that comes together, are aligned. There's no gap.
The last friction is on the offset groove
When i tighten the 4 clutch spring bolts down to 80 in pound, it looks like the springs are almost completely compressed. Is that normal? When i have it half way in, i can compress the clutch by hand and see the 2 piece seperate, like how i imagine would happen when you pull the clutch lever in
i have the basket nut with the washer on at 60ft pound. When i button everything up, i still cant pull the clutch lever, it feels like it's stuck.
Any advice would be much appreciated. Here's some photos of the clutch assembled before going into the basket. I don't know how to add photos, so here's the link the my album. https://photos.app.goo.gl/4u4Pbpf5GQFQHxuB7
ss109 wrote: 03:02 pm Jun 11 2026
Something in your stack is wrong. Can you post a pic on the exact order you have it in? Here is how to post a pic: viewtopic.php?t=24128
Here's a picture of the clutch stack.
Clutch Hub.jpg (510.66 KiB) Viewed 111 times
I also noticed some burrs on the edges of the clutch pack that mesh together with the clutch wheel. I had the clutch pack in the basket and took the 4 spring bolts out and tested pushing and pulling on the clutch wheel by holding on to those 4 towers and it was sliding in and out but not freely. Could those burrs causing it to be stuck when under tension when the springs/bolts are installed?
MeanGreen02 wrote: 08:25 am Jun 12 2026
I also noticed some burrs on the edges of the clutch pack that mesh together with the clutch wheel. I had the clutch pack in the basket and took the 4 spring bolts out and tested pushing and pulling on the clutch wheel by holding on to those 4 towers and it was sliding in and out but not freely. Could those burrs causing it to be stuck when under tension when the springs/bolts are installed?
Anything is possible. I would take a small file to those burrs and dress them. Then check it again for movement. By any chance, did you check your spring length and, if so, what is it?
MeanGreen02 wrote: 08:25 am Jun 12 2026
I also noticed some burrs on the edges of the clutch pack that mesh together with the clutch wheel. I had the clutch pack in the basket and took the 4 spring bolts out and tested pushing and pulling on the clutch wheel by holding on to those 4 towers and it was sliding in and out but not freely. Could those burrs causing it to be stuck when under tension when the springs/bolts are installed?
Anything is possible. I would take a small file to those burrs and dress them. Then check it again for movement. By any chance, did you check your spring length and, if so, what is it?
I should have used a caliper but a quick check with the tape measure was pretty close to 1.5in. My stack is in the right order right?
