Clutch basket rebuild

Got questions? We got answers....
Post Reply
JoshJHTX
Member
Posts: 11
Joined: 05:51 pm Aug 09 2020
Country: United States

Clutch basket rebuild

Post by JoshJHTX »

Putting together my clutch after tearing down doing a water pump rebuild, where tf do these things go? Concave large rings I believe there’s two
Attachments
IMG_3223.jpeg
IMG_3223.jpeg (2.12 MiB) Viewed 972 times
kdxdazz
Member
Posts: 568
Joined: 07:51 am Dec 28 2017
Country: thailand
Location: Thailand

Re: Clutch basket rebuild

Post by kdxdazz »

Those are the judder springs, very important for slow speed technical riding, refer to service manual on how they fit, I don't have a service manual handy to show you
1999 KDX220SR (KDX220-B5)
User avatar
Chuck78
Gold Member
Gold Member
Posts: 1186
Joined: 06:20 pm Nov 30 2016
Country: USA
Location: Columbus, OH

Re: Clutch basket rebuild

Post by Chuck78 »

kdxdazz wrote: 07:54 pm Nov 10 2024 ...the judder springs, very important for slow speed technical riding
Hey Daryl, can you describe to me why the judder springs are very important to slow speed technical terrain riding in particular?
I'd learned that I believe when you omit them, and run an extra clutch disc, the clutch is more grabby and instantaneous, but also when disengaging the clutch, makes the bike freewheel much more smoothly.

Does the judder spring's engagement allow for a significantly greater amount of modulation, therefore reducing the breaking of traction that may ensue with a more rapid engagement if theyre deleted?
'97 KDX220R - purple/green! - KLX forks, Lectron, FMF, Tubliss
'99 KDX220R project - '98/'01 RM125 suspension, Titanium hardware, Lectron Billetron Pro, Tubliss
'77 Suzuki PE250 & '83 Suzuki PE175 Full Floater - restomod projects
'77 Suzuki GS750-844cc, '77 GS400/489cc & '77 GS550/740cc projects
'62 GMC 1000 Panel Truck
'88 Suzuki Samurai TDI/Toyota swaps
'88 Toyota 4x4 pickup
User avatar
bufftester
Platinum Member
Platinum Member
Posts: 3545
Joined: 06:03 pm Oct 31 2012
Country: USA
Location: University Place, WA
Contact:

Re: Clutch basket rebuild

Post by bufftester »

The judder spring smooths out the engagement of the clutch, effectively making it less on/off and in theory improving the modulation. There should be a conical one (the judder spring) and a flat one (the seat). The seat goes on the clutch hub first followed by the judder spring such that the concave side is facing away from the seat.

Also, make sure you get the washer stackup correct when reassembling the clutch or it will have issues.
kdxdazz
Member
Posts: 568
Joined: 07:51 am Dec 28 2017
Country: thailand
Location: Thailand

Re: Clutch basket rebuild

Post by kdxdazz »

Chuck78 wrote: 12:20 pm Nov 13 2024
kdxdazz wrote: 07:54 pm Nov 10 2024 ...the judder springs, very important for slow speed technical riding
Hey Daryl, can you describe to me why the judder springs are very important to slow speed technical terrain riding in particular?
I'd learned that I believe when you omit them, and run an extra clutch disc, the clutch is more grabby and instantaneous, but also when disengaging the clutch, makes the bike freewheel much more smoothly.

Does the judder spring's engagement allow for a significantly greater amount of modulation, therefore reducing the breaking of traction that may ensue with a more rapid engagement if theyre deleted?
As bufftester said it makes the clutch less grabby, I spent quite a few hours taking them in and out and testing as I read so many things about just take them out, as usual it turned out to be nonsense, all Japanese bikes run a judder spring set up and for good reason
Just like a light switch throttle can become tiring so can a grabby clutch, yes not noticeable in fast flowing but manufacturers can't just make things only for fast flowing and the kdx is also a street registered bike in many and most countries so trying to make your way through traffic with a grabby clutch is very unpleasant
As you also stated removing the judder springs will allow the clutch to completely disengage with far less movement of the clutch lever but I could only see this as an advantage for people with very small hands , I have small hands that's why I can see the advantage
The kdx is known for having a clutch that is not great at disengaging, I don't exactly understand the reasons for this but I am getting closer, was working on my nsr150 clutch yesterday and discovered the steel plates are the same as the kdx as is the first narrow clutch plate that surrounds the judder springs, amazing Honda and Kawasaki have so many shared parts
I think from memory we are both the same age and it's around this age that you start to appreciate things being more refined and user friendly
1999 KDX220SR (KDX220-B5)
Post Reply