kdx 220 fricton plates. trouble getting them on

[Tedh98]

Could it be the springs? Maybe the old ones are just too old and the new ones just aren't the right ones? They seem to be a coil and a half taller, soooo?

The aftermarket springs I bought didn't work, so who knows. But with those springs, the clutch didn't slip, I just couldn't release the stack all the way because the coils bound before it fully disengaged.

With your clutch all installed, can you move the frictions around at all, like with a screwdriver? I'm not saying to dig in there and pry hard, just a little effort to see if the springs are clamping things tight.

[superman27e]

I pushed pretty hard with my hand. Pretty sure they're not going anywhere

[KarlP]

KarlP wrote:
Keep at it. You were almost there.

Maybe I am reading too much into this, but do you know what the issue is?

No, I don't know exactly what is wrong. Review the posts I quoted. It looked like he almost had it, then decided to leave the big round spring and seat out.

Superman, sit back, take a minute, put it back together per Teds video.

I usually have to assemble and re-assemble my clutch three times to get it right, and then still don't know what I did, exactly.

[Tedh98]

No, I don't know exactly what is wrong.

Ok, I thought maybe you were pulling one of those dad moves where he lets his kid struggle until he figures it out, and the whole time he knew the answer or what the problem was.

[superman27e]

It's weird. The friction and steel plates are tight like they should be and everything is torque down to spec. But it slips like crazy. If I do anything but baby the throttle it slips and rev almost like it's in neutral.

[superman27e]

Do you think it could still be the basket causing problems?

[superman27e]

So I took everything apart and put everything together again and still didn't work. I got pissed, snatched the cover off and torque the crap out of the springs screws. Still slips, but not as bad. I'm gonna cool off and torque it down a little more and see what that does

[Tedh98]

Not sounding like a good idea. The torque spec on those isnt much. And once the bearing plate hits the top of the 4 posts on the pressure plate, it wont go any further no matter how much you torque the bolts.

[superman27e]

Game over. In my dumb rage, I torque it too much and broke the head off of the spring screw. Taking it to the shop and let them deal with this damn thing and rob my wallet.

I really do appreciate all of your help, though :)

[Tedh98]

Bummer, sorry to hear that.

Please post back with what the shop found wrong with it - other than the broken part.

[superman27e]

I definitely will. Thanks again :)

[bufftester]

At least you didn't break the spring plate...the only place to get one is off another bike.

[superman27e]

What about the cable? I just noticed it has absolutely no play at the clutch lever at all. That'd explain when it's slipping way more with the new friction plates. They're thicker.

I have a new motion pro clutch cable and there's two adjusting points on it. I've never adjusted one, so how would I do that?

[royadams]

That would do it. To adjust you loosen the locking nut and turn the adjusting in to gain more free play, making the cable housing shorter. It wont help much now that you snaped one of the bolts. You probably won't be able to release the clutch it will stay engaged .

[Tedh98]

Here is a thought for you - try to get that screw out yourself or replace the part and get a basket that is in better shape. A shop is probably going to replace those parts with new ones (along with their mark up) rather than mess with getting the screw out or dealing with your basket that has so much "character". The cost of those parts alone will be a lot.

If you can give them a clutch that is in better shape, then you have a chance at paying labor only. Of course they could still insist that you still need new parts.

[Tedh98]

If you want to haul your bike over here one day, we can figure it out. I am pretty sure I have all the parts to make an entire clutch assembly. I may be short two springs, but I know I have all the major parts.

[superman27e]

Really? That'd be awesome! I'm free tomorrow if you'd want to do it then?

[Tedh98]

Check the email you provided on page 2. I just sent an email to you and want to make sure I have the correct one.

[superman27e]

I got your email

[superman27e]

I fixed it! Instead of adjusting the cable, I just uncool it, started the bike, rolled down the hill and popped it in first and off I went. No slipping at all! It was because the old plates were worn out and thinner compared to the new thick plates. The clutch was always engaged a little :)