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I did a first time top end rebuild om my KDX 200 2005. It still had the original size piston in, I went one size up with a Wossner rebuild kit. Cleaned all the grime in the KIPS system and reassembled. I did have to replace the pin on the governor arm since when I loosened the bolt to pull the top off, my 6mm spanner holding the governer shaft snapped and as a result the pin got bent.
After reassembling everthing, I put in new oil and radiator mix and started it. Wanted to go for a test ride today but when I put it in gear, it wont move. I adjusted the clutch cable, which is suddenly now very hard to pull, which it wasn't before. Started and tried again, and it stalled as soon as I put it into first. Tiny adjustment on the clutch cable and its back to before where it's not moving.
Has the clutch gone? If so, why so suddenly?
Or what could be the problem?

If you replaced the pin on the bottom of the KIPS actuator shaft coming out of the bottom end, that means you have had the clutch case off in order to do this repair. Something was not reassembled correctly, or else the broken portion of the kips actuator pin is jammed up in your clutch basket somehow.
I'd imagine you're going to have to pull the clutch case apart again. The problem lies there, it's very unlikely that you burnt up your clutch without running the bike. Something is out of place and or jammed.

Kips valve check video.

I think chuck is on the money, governer pin has nothing to do with the clutch, can only be the way you reinstalled the clutch cover

When you say pin, do you mean the pin inside the clutch cover? The one that fits in the channel on the ball and ramp mechanism?

KDXGarage wrote: 03:37 am Jan 08 2025 When you say pin, do you mean the pin inside the clutch cover? The one that fits in the channel on the ball and ramp mechanism?

Yes, that's what I was referencing, and I'd speculate that's what the original author meant as well.

I am wondering if he bent the top pin and broke the bottom pin.

I suppose he could have damaged the pin on the top and not actually taken the clutch case apart to look at the lower pin, but I assumed it was the lower pin he was talking about. He's probably not getting notifications but will likely chime in at some point here.

We lead exciting lime green lives. :-)

Molly's: that's a useful video above. Thank you.