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I tore down the engine of my 1991 Kdx 200 a few months ago, got a new piston/rings and full new gasket set up. Well I got side tracked and just forgot about it for awhile. So I put it back together yesterday, all went well until I went to put the clutch cover on, it was a fight (I did not remove the clutch its self, just the 5 bolts with springs) the clutch seems to be pushing up on the cover and the handle is really hard to pull/ with no spring back. I know I did something wrong but its been to long from when I tore it down, any suggestions?

You took out/off only the bolts and springs?

Why did you do that? To what end?

Explain how you put the bolts/springs back in.

You torqued them to....what?

'..pushing UP on the cover.'???

Up?

Describe the 'clutch cover'.

Clutch cover = round case over the clutch with 6 bolts.

I just put the bolts back in didnt really torque it down that hard..... maybe 15 ft lbs, thinking the plate needed some spring action to make the clutch work, prolly wrong on this part.....

pushing up the cover was vague sorry, its pushing out agaist it, instead of just bolting on persay, if I wanted to install that cover I would have to use the bolts to actually torgue it into place

Honestly I dont know the reason it came off, dont even remember why or if I did it, had someone helping, had way more stuff come off then i really needed in the end...

Tighten those clutch bolts down... they don't work off of the springs!

Then make sure your actuator arm is seated in the bottom hole of the cover before you put the cover on and you should not have any problems....

Whoa!!!!!!!!


STOP!!!!

The torque on those bolts is QUITE small!!!! That was the point of my question. REEF on 'em and you will break the pedestals they thread into..and you may have exactly what you gots now!!!

Did you use a torque spec? Do you know what it is?

Yeah...the actuator rod IS square to the cover, right? It's not wonky (indicating what Inda said).

Well now...sure a lot of answers posted here in the last hour or so..


The spec in the 'H' manual is 78INCH/lbs.

That's 6 1/2 ft/lbs.

At the 15ft/lb stated, that's approaching 2 1/2 times the spec value.

Time to take it apart and find out what's wrong...look for broken bolt bosses.

I also suspect actuator rod is not on the flat spot.

Get a manual. Get a torque wrench. Learn to use it. With these bikes, it's pretty important to not overtighten anything.

Ain't that the truth!

canyncarvr wrote:
The spec in the 'H' manual is 78INCH/lbs.

That's 6 1/2 ft/lbs.

At the 15ft/lb stated, that's approaching 2 1/2 times the spec value.

Well, I'm not even 6 1/2 feet so when I stand on the socket wrench it should only torque it to say....50 inch pounds?

Serious though.... when those bolts tighten up... I just snug em a little more. I don't feel there is a reason to use a torque wrench on those myself but for those that are new to mechanicin.... I would suggest it.

Thats all i do. Get em tight, then just add a little nudge.

Get used to a torque wrench and soon your hand becomes educated as Vince is hinting at. If you don't know what 6 ft lbs of torque feels like compared to, say, 12 ft lbs of torque, then get the wrench out.

I have no problem with an educated torque arm. The PROBLEM is one guy's 86in/lb may be another guy's 20ft/lbs. If that's the way either of 'em wants to wrench on stuff, I could not care any less than I already do (just stay away from MY stuff!).

You guys have all heard stories of over-wrenched stuff. Ex: After six years of riding and air filter services every couple of rides, my seat bolts/inserts are still fine. I've known more'n one guy that busted/stripped/goobered his within a month!!!

I know of riders that have misread the spec for the axle caps as FT/LB and proceeded to bust the studs off. WHO is going to look at a 1/4" fastener and think 80ft/lbs as a torque spec is within light years of the CORRECT value?

In this case, the parts were A-part, reassembled and now they don't work. Overtightening those bolts would get you to exactly this situation. I'm not dinging on you ricke. You may well know exactly what you're going torque-wise...but, I don't know that.

In this case, because you are wrenching against a spring tension, when the fastener feel changes from twisiting against that tension to twisting against the threads gets a bit iffy.

HOW could the actuator NOT be on the flat without the actuating LEVER pointing into space?

BTW...that actuating lever should travel THROUGH a 90º angle from clutch lever release to full pull. Is that clear? It's an arc that will provide the MOST amount of 'travel' (movement) of the edge of that flat on the shaft.

It takes a casual glance to get that point if you have any spatial reckoning a'tall.

I hope it's something simple!! If the pedestals are split, it's time for a Hinson Basket ($200...without the gear on the back).

Inda wrote:Well, I'm not even 6 1/2 feet so when I stand on the socket wrench it should only torque it to say....50 inch pounds?

Eggsactly!

Check the Springs. They can bind up during install if you are not tighting every other bolt. The clutch arm could also NOT BE in the flat spot. When you put the cover on, you have to move the arm at least 9 o'clock counter clockwise to getr the clutch cover to mate up with NO FORCE. Then you move the arm into position.

Ok figured it out, I didnt put enough torque on the bolts. I totally pooched what I said eariler. I didnt tightened the bolts down at all basically I got to where the springs started to compress and stopped, 15lbs was a horrible guess, I stuck a torque wrench on it just to see what it clicked at, didnt get anything at the lowest setting........ yah Im real bright

So basically that whole thing was pushing out agaist the clutch cover case, not a mistake I will make again. ut thanks for the info and its installed right and working now, should be able to test start it tommorrow, just have to put minor plastics and such on now.

Thanks again, feel free to flame cause I deserve it at this point.

Hey, NEVER KICK A BROTHER WHILE HES DOWN
YEAH RIGHT

Better too loose than too tight, broken, lot'sa $$$ to fix stuff.

Good to hear it's OK.