kdx 220 fricton plates. trouble getting them on

[superman27e]

I still have to work the frictions down a little. They get a little stuck sometimes. But the hub and pressure plate seem fine. No signs of wear or anything.

When I bought it, it was fine. I rode it for a month or 2 before it started slipping.

[superman27e]

I didn't remove the springs. I had just put the socket on it, gave it a small twist and the clutch rod shot out :p

[Tedh98]

I still have to work the frictions down a little. They get a little stuck sometimes.

I would work on the basket some more then. You dont want a sloppy fit so try to identify exactly where they are hanging up and remove as little material as possible. As I mentioned, they should drop right down on their own.

[superman27e]

Gotcha. I'll go do that now and let you know how it goes. Keep your fingers crossed!

[superman27e]

Well, I guess they're moving freely enough. Do you think I still need to file it some more?

http://youtu.be/e3bUNJPvqQ8

[Tedh98]

More important question rigt now, what chewed up the outside of your basket?

[superman27e]

Pretty sure it was the broken friction plate.

[superman27e]

Ok, I filed it down a little more and now they drop in easily.

[superman27e]

I'm not 100% sure it's the basket. I mean, they're moving up and down with no snag at all. I just put it back together after filing it down, and once again, the rod decided it wanted to go too far in. Put the cover on anyways and there's too much slack in cable again. Started it up, put it in 1st and it just revs.

[Tedh98]

I have to say I am running out of ideas.

How about trying to eliminate some variables? What happens if you install the hub, frictions, steels and pressure plate, but leave the pushrod, bearing, cable and cover off and try to roll the bike in first gear?

[superman27e]

Probably would do the same thing with the rod and stuff on. I'll have to try it out tomorrow.

[Tedh98]

Probably so, but at least with the cover off you can get a better look at what is going on.

If the bike rolls easily in gear with the cover and cable off, then you need to find out what is keeping the springs from applying enough pressure to properly clamp the clutch pack together. Should be easy with only the basket, hub, pressure plate and frictions/steels in there.

[6 Riders]

Could it be that he has the wrong "pusher" bearing and the pusher is pressing into the bearing? Or the clutch pusher holder is installed wrong?

EDIT....Or the spring and spring seat backwards?

[Tedh98]

I saw your post on TT, it says you are from Georgia. What part?

[superman27e]

Milledgeville. About an hour from Atlanta.

[superman27e]

Could it be that he has the wrong "pusher" bearing and the pusher is pressing into the bearing? Or the clutch pusher holder is installed wrong?

EDIT....Or the spring and spring seat backwards?

Which way is the right way to install the seat and spring seat? I thought they went on facing the same direction?

[Tedh98]

Milledgeville. About an hour from Atlanta.

If we were closer (I am near Fayetteville) I would drive over with a complete clutch and help you figure this out once and for all.

[Tedh98]

Which way is the right way to install the seat and spring seat? I thought they went on facing the same direction?

It looks like you have it correct in your video.

[royadams]

I see what your problem is you have the last friction plate in wrong. They all go in the same groove. You have the last one see in the notch on top of the basket not letting it compress the stack.

[Tedh98]

I see what your problem is you have the last friction plate in wrong. They all go in the same groove. You have the last one see in the notch on top of the basket not letting it compress the stack.

That by itself shouldnt be the problem. Most KDX clutches I have seen or owned had that last plate like that. The manual also shows it installed that way. I have no idea why though.

I think it throws people off that the KDX clutch operates in reverse of most other clutches. The clutch pack compresses towards the pressure plate or away from the engine. That is why that last friction can be installed that way and still work.

Now he could pull it apart and orient all frictions the same way ( which is how I used to run them) and the clutch may start working. But that is because I think something is fundamentally wrong in the setup. Maybe I am reading it wrong, but I get the idea that the bike is rolling easily in gear with no compression/force on the pressure plate or pushrod.