Clutch Question

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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MeanGreen02
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Joined: 02:31 pm Jun 08 2026
Country: United States

Clutch Question

Post by MeanGreen02 »

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
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ss109
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Re: Clutch Question

Post by ss109 »

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
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