1988 kdx 200 clutch springs

kdxdan · Post by **kdxdan** » 10:36 am Aug 24 2015

Hello all,
I have a question about clutch spring tolerances. I checked the length of the clutch springs on my 88' 200 and they measured 31.2mm (1.23"). The manual says standard relaxed/free length should be 20.6mm (.81"). Am I missing something? Has anyone encountered this?
Thanks!

scriberman · Post by **scriberman** » 01:14 pm Aug 30 2015

20.6 is a compressed length and should be 13-15kg at this dimension. Guess your looking at the clymer manual? If it's not slipping don't worry.

kdxdan · Post by **kdxdan** » 05:19 pm Oct 06 2016

No, the clutch doesn't slip, It doesn't disengage. When the bike is running and I go to put it in gear, I jumps a little then stalls. Almost like the plates are stuck to the metal plates

Post by **KDXGarage** » 05:37 pm Oct 06 2016

Which manual are you using?

I have the OEM manul, and it says the test length, not the free length. If it takes less than 25.8 inch - pounds of force to squeeze it to 20.6 mm, then the spring is worn out.

No. I have no idea how in the world one checks that.

Odd to see you reply 13 months later.

Post by **bufftester** » 07:13 pm Oct 06 2016

You have to use a spring checker, The problem is finding one that works at the small values needed for the clutch springs, most are designed for testing valve springs in cars.

Post by **KDXGarage** » 11:25 pm Oct 06 2016

sum bich, yet another tool I don't have

JL4049 · Post by **JL4049** » 02:11 pm Oct 07 2016

You can use digital kitchen scales and a drill press.
Set scales on drill table, if the chuck on the drill will not fit inside the spring when it's closed right up, get an old valve from a 4 stroke and cut part of the stem off, giving you a flat anvil to press down on the Spring (and a good edge to measure from it just so happens) if the kitchen scales do not read high enough, use bathroom digital ones, they normally read down to 0.1g. I hope this is of some help.

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