03 clutch replacement help

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
Post Reply
masonkdx200
Member
Posts: 26
Joined: 07:57 pm Oct 29 2012
Country:
Location: Mattapoisett MA

03 clutch replacement help

Post by masonkdx200 »

hi guys im in the middle of rebuilding my rm hybrid and am having some issues with the clutch. I filed the basket and followed a diagram when putting together. when its all together it either feels like neutral doesnt want to work. (it feels like its almost in gear). so i will try again and then sometimes the clutch wont even want to work , but then neutral is fine. im sorry if im not explaining this very well but any help would be greatly appreciative. thanks!
masonkdx200
Member
Posts: 26
Joined: 07:57 pm Oct 29 2012
Country:
Location: Mattapoisett MA

03 clutch replacement help

Post by masonkdx200 »

when i say the clutch doesnt want to work i mean it doesnt want to pull in.
User avatar
Tedh98
Supporting Member II
Supporting Member II
Posts: 1576
Joined: 01:08 pm Mar 20 2009
Country:
Location: Atlanta, Georgia
Contact:

Re: 03 clutch replacement help

Post by Tedh98 »

Try putting it together like this:

[youtube][/youtube]
Last edited by Tedh98 on 10:09 pm Feb 15 2015, edited 1 time in total.
masonkdx200
Member
Posts: 26
Joined: 07:57 pm Oct 29 2012
Country:
Location: Mattapoisett MA

03 clutch replacement help

Post by masonkdx200 »

Thank you but the link is not working lol
GI_JO_NATHAN
Supporting Member I
Supporting Member I
Posts: 223
Joined: 06:07 pm Dec 14 2014
Country:

Re: 03 clutch replacement help

Post by GI_JO_NATHAN »

Works for me.
masonkdx200
Member
Posts: 26
Joined: 07:57 pm Oct 29 2012
Country:
Location: Mattapoisett MA

03 clutch replacement help

Post by masonkdx200 »

Okay It works now. Its a great video. Thank you
masonkdx200
Member
Posts: 26
Joined: 07:57 pm Oct 29 2012
Country:
Location: Mattapoisett MA

03 clutch replacement help

Post by masonkdx200 »

Well im stumped. I followed the video and doing everything correctly. As soon as I start to tighten down the clutch springs neutral starts to feel like is a gear. Whats could be wrong!!?
User avatar
ICRage42
Supporting Member
Posts: 598
Joined: 07:24 am Jan 09 2013
Country:
Location: Kawasaki, Ninja Ohio

03 clutch replacement help

Post by ICRage42 »

you might want to try and swap the old springs on for a bit and let the plates work some and then put the new ones back on. I had a horribly hard clutch as in what you said and I think read here somewhere to try that and it worked. It was still somewhat hard for the first couple of times and then felt real good put the new springs back on and was harder to pull clutch but felt good.

Well the fact you have checked its easy to open up and run through it again. Lord knows I have about 30 or so on my first clutch pack replacement. :rolleyes:
If you cant fix it with a hammer, you have an electrical problem.
masonkdx200
Member
Posts: 26
Joined: 07:57 pm Oct 29 2012
Country:
Location: Mattapoisett MA

03 clutch replacement help

Post by masonkdx200 »

Something is wrong and I just cant figure it out. Im going to work on my ktm for a while and give this a break haha
Post Reply