kdx 220 fricton plates. trouble getting them on

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superman27e
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kdx 220 fricton plates. trouble getting them on

Post by superman27e »

Just got my new clutch kit. I tried to slide the friction plates on, and it won't go. The ones I took off were difficult to get off too. I broke two trying to get it off. Should it be this hard?
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scheckaet
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kdx 220 fricton plates. trouble getting them on

Post by scheckaet »

don t forget to soak them before putting them on.
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Tedh98
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Re: kdx 220 fricton plates. trouble getting them on

Post by Tedh98 »

Is it difficult getting them on the hub or in the basket?
superman27e
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Re: kdx 220 fricton plates. trouble getting them on

Post by superman27e »

In the basket. I got them all in there after filing the fingers a bit. But now the clutch won't engage. I don't have a torque wrench right now, so I didn't torque the clutch springs down to spec. Could the clutch springs being too loose or tight keep it from engaging?
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Re: kdx 220 fricton plates. trouble getting them on

Post by superman27e »

Also, the clutch lever won't pull all the way in, if that helps any.
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Re: kdx 220 fricton plates. trouble getting them on

Post by Tedh98 »

Are any of the clutch fingers bent or distorted?

And yes, something is wrong if you are having to try that hard to get new ones on or breaking the old ones getting them off.
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Re: kdx 220 fricton plates. trouble getting them on

Post by superman27e »

Also, my manual mentions a coned disc spring the goes between the top two friction plates. But, when I took the clutch off, I never saw one. Also, is there supposed to be a washer between the "clutch pusher arm" and the little bearing thing it slips in to? I know there a small shim like washer, but is there a bigger on?
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Re: kdx 220 fricton plates. trouble getting them on

Post by KDXrider1989 »

taking the plates off and reinstalling them shouldn't be an issue at all unless severely warped like Ted mentioned. the clutch spring bolts are gonna be tightened all the way down like any other bolt, but yes you do wanna check on proper torque, not that a little too much won't hurt just try not to strip the threads. you're engagement issue sounds like something on the pushrod assembly that wasn't installed correctly, look on bike bandit.com for a parts diagram to see how everything lines up and what goes where
superman27e
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Re: kdx 220 fricton plates. trouble getting them on

Post by superman27e »

10-4. I checked and it looks like I'm missing a washer that goes between the inner hub and the clutch basket. But could that make it not engage?
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Re: kdx 220 fricton plates. trouble getting them on

Post by Tedh98 »

superman27e wrote:10-4. I checked and it looks like I'm missing a washer that goes between the inner hub and the clutch basket. But could that make it not engage?
Without that washer you are sandwiching the inner hub and basket together. That washer spaces them apart so the can rotate independent of each other.
superman27e
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Re: kdx 220 fricton plates. trouble getting them on

Post by superman27e »

Thanks for the info, guys! It was because the washer wasn't between the inner hub and basket. I found stuck together with the washer that goes behind the basket. :p Now, time to ride in this rain!
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Re: kdx 220 fricton plates. trouble getting them on

Post by superman27e »

Spoke too soon. Now it's slipping worse than before. Any ideas?
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Re: kdx 220 fricton plates. trouble getting them on

Post by Julien D »

What kind of oil did you use?
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superman27e
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Re: kdx 220 fricton plates. trouble getting them on

Post by superman27e »

Regular non synthetic 10-40. I've always used it
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kdx 220 fricton plates. trouble getting them on

Post by Tedh98 »

superman27e wrote:Just got my new clutch kit. I tried to slide the friction plates on, and it won't go. The ones I took off were difficult to get off too. I broke two trying to get it off. Should it be this hard?

This has to be related to your problem. I have never had frictions plates that were difficult to get on or off.
superman27e
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Re: kdx 220 fricton plates. trouble getting them on

Post by superman27e »

You think that'd make it slip, though?
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Re: kdx 220 fricton plates. trouble getting them on

Post by superman27e »

Would a clutch basket from a 99 200 fit on my 99 220?
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kdx 220 fricton plates. trouble getting them on

Post by scheckaet »

they're the same.
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Re: kdx 220 fricton plates. trouble getting them on

Post by superman27e »

I was just taking it off again to check everything out and noticed that the inner hub is spinning freely with almost no resistance at all, other than it spinning the steel plates. Is it supposed to move that freely?
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Re: kdx 220 fricton plates. trouble getting them on

Post by Tedh98 »

If your transmission is in neutral it would rotate pretty easily. If your transmission is in gear it shouldnt rotate.
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