Clutch Question
Posted: 09:27 am Jun 11 2026
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:
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
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