Stiff Clutch

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
Post Reply
bergilong
Member
Posts: 42
Joined: 12:59 pm Aug 13 2016
Country: USA
Location: Arkansas

Stiff Clutch

Post by bergilong »

I replaced the clutch plates, springs(heavy duty), and cable on my KDX200. The clutch pull was insanely hard. I had to use two hands to pull the clutch in. I put the old clutch springs back in and it helped a lot, but the clutch pull is still harder than normal. Any ideas?
david
Member
Posts: 524
Joined: 08:30 pm Oct 10 2011
Country:
Location: Forney, TX

Re: Stiff Clutch

Post by david »

Cable routing? Is the cable itself binding or kinked?
'81 KDX 175
'90 KDX 200
'07 Vulcan 2000 Classic LT (totaled 4/25/15)
'82 Honda GL500 (sold)
'96 ZXi 1100 JetSki
'98 STX 1100 JetSki
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

Stiff Clutch

Post by SS109 »

Cable routing would be first check. I also lube new cables to make sure they are lubed well. Was your clutch basket really notched?
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
bergilong
Member
Posts: 42
Joined: 12:59 pm Aug 13 2016
Country: USA
Location: Arkansas

Stiff Clutch

Post by bergilong »

SS109 wrote:Cable routing would be first check. I also lube new cables to make sure they are lubed well. Was your clutch basket really notched?
My clutch basket was really notched, but I filed it down. I'll check cable routing.
User avatar
6 Riders
Gold Member
Gold Member
Posts: 2124
Joined: 12:58 pm May 01 2013
Country: USA
Location: Washington
Contact:

Re: Stiff Clutch

Post by 6 Riders »

Check to make sure all your bolts are torked to spec. You can get a hard pull If the bolt holding the clutch to the shaft is loose at all.

Sent from my BLN-L24 using Tapatalk
newbbewb wrote:^what he said.
masterblaster wrote:Man 6 riders you rock.
*side note...I'm drunk, so try to read what I'm trying to say, instead of what I actually type
Post Reply