KDXRIDER.NET

I recently installed a new clutch (only fibers and steels) in my '05 KDX200.
Now, the clutch starts to slip at high revs, under load. Basically, if I'm going up hill and rev it into the power band, it suddenly starts revving to the redline, without the acceleration to match.
I know it's not the cable - There's still slack when I'm off the lever, even when hot.
The replacement clutch kit was a budget one. I didn't check the thickness of the stack. It was the night before a race, so I just threw it in.
Are there any heavier springs that I can install - either aftermarket or from another model of bike that will help to clamp my clutch better?

I never use the budget clutch packs, that seems to be your problem there. Honda XR400R friction discs (Vesrah brand, Made in Japan) & KDX steel plates + 1997-2006 KDX clutch springs so far for me work great, with a slightly larger friction surface area than the original KDX friction discs). Jeff Fredette sells the Vesrah Honda XR350/250/CBR/etc friction discs in sets for the KDX, as none of the Honda models contain the correct amount for the KDX in their multi-packs, so you'd have to buy two sets of the Honda kits to have enough for the KDX.
I have been wanting to get aftermarket springs from EBC or Barnett, they are said to be 10% firmer than stock for better holding power, but I was going to use that in conjunction with a longer clutch release arm to lighten up the effort back to stock but have more positive engagement.

That could potentially fix your issue, but if you are slipping the clutch a lot, I would be concerned about the longevity of those aftermarket friction linings.

Did you by chance change to a different type of oil at the same time as the new clutch friction discs?

I was wondering if the budget clutch might be the issue.
I used the same oil I always do - Penrite 10W40 MC4ST.
I'll look into the XR plates.
Thanks for the info.

You'll want to get the Vesrah Honda XR friction discs from Jeff Fredette if you go that route, https://www.frpoffroad.com/site/contact.html , as the kits for the Honda models don't come in the correct quantity for the KDX, so you'd have to buy two kits. They fit many Honda models, XR400R was the one I recall, old XR350R, older XR250R, some CBR sport bikes, etc...

Or just get the aftermarket kits from EBC or Barnett.

Does anyone else have any feedback as to good higher end aftermarket clutch disc brands? I have bought OEM Kawasaki in the past. The OEM Honda are quite expensive, and Kawasaki weren't cheap at all. I always buy the OEM Kawasaki steel plates, but Vesrah Honda friction discs or OEM Kaw friction discs.


There is a slight chance that you could have assembled something wrong, but I am having trouble picturing what could cause slipping on reassembly, as I believe most installation errors (parts omissions, thrust washer etc) will cause the opposite - they will cause the clutch to not fully disengage.

Does Barnett make a kevlar version of the XR pads? They would be more heavy duty.

In my experience Rocky Mountains Tusk clutch with springs worked great on my RB head, pipe, V Force, 35mm carb'd 220. It's like $65 and I had it in there for a couple of years. It gets 4.5 star rating with over 500 reviews. The only reason I switched it out is because I found a full OEM steel, friction, and springs new in the packages on Ebay for under $100. The new OEM was no better or worse.

John_S wrote: 11:06 am Jun 03 2026 In my experience Rocky Mountains Tusk clutch with springs worked great on my RB head, pipe, V Force, 35mm carb'd 220. It's like $65 and I had it in there for a couple of years. It gets 4.5 star rating with over 500 reviews. The only reason I switched it out is because I found a full OEM steel, friction, and springs new in the packages on Ebay for under $100. The new OEM was no better or worse.

I know that my Honda friends say the Tusk clutch is absolutely do not hold up in their bikes, and they insist on oem. Honda does appear to use a lesser quantity of friction discs than kawasaki, however, so that may be part of the reason for that complaint.
The surface area of each of the individual friction lining pads on the Barnett clutches was smaller than what the vezra or OEM Honda or OEM Kawasaki versions were, so I skipped over their offerings, however, I suppose with improved material, it very well could still function better. I have not personally tried them, but I am curious to know what the feedback is from those who have used Barnett clutches in our bikes.

In the Barnett catalog, I believe the Honda application / Honda part number that we use for obtaining the upsized friction linings that are a drop in replacement for the KDX friction discs, is also the same Barnett art # as the KDX friction discs, however, most other aftermarket brands keep them more true to their original sizing of friction linings with separate manufacturer part numbers for the Honda versus the KDX version.