89 clutch issues tried the regular fixes. Now what?
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89 clutch issues tried the regular fixes. Now what?
I'm having this haunting issue with my new to me 89 clutch.
It doesn't dissengage fully, in fact it barely lets me go forward without revving the heck out of the engine then leaps forward when I shove it into first.
This sounds like sticking clutches, but I soaked them all in trans fluid,
SOunds like buggered basket but I filed down the high spots.
I'm thinking it's my lever or my actuator. When I turn the actuator with a wrench more than the clutch lever pulls it engages the clutch and I can shift just fine. I have adjusted the cable slack to spec or tighter, and have welded and reground the actuator and pin to a tighter tollerance to no avail. I think I have an aftermarket lever on there, is it possible it isn't pulling enough, I'll take some pics.
http://s264.photobucket.com/albums/ii18 ... G_1152.jpg
http://s264.photobucket.com/albums/ii18 ... G_1153.jpg
http://s264.photobucket.com/albums/ii18 ... G_1154.jpg
http://s264.photobucket.com/albums/ii18 ... G_1155.jpg
It is teaching me to be a smoother rider though......
It doesn't dissengage fully, in fact it barely lets me go forward without revving the heck out of the engine then leaps forward when I shove it into first.
This sounds like sticking clutches, but I soaked them all in trans fluid,
SOunds like buggered basket but I filed down the high spots.
I'm thinking it's my lever or my actuator. When I turn the actuator with a wrench more than the clutch lever pulls it engages the clutch and I can shift just fine. I have adjusted the cable slack to spec or tighter, and have welded and reground the actuator and pin to a tighter tollerance to no avail. I think I have an aftermarket lever on there, is it possible it isn't pulling enough, I'll take some pics.
http://s264.photobucket.com/albums/ii18 ... G_1152.jpg
http://s264.photobucket.com/albums/ii18 ... G_1153.jpg
http://s264.photobucket.com/albums/ii18 ... G_1154.jpg
http://s264.photobucket.com/albums/ii18 ... G_1155.jpg
It is teaching me to be a smoother rider though......
Fletch
89 kdx 200 with 99 rm125 forks
89 kdx 200 with 99 rm125 forks
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There should be no space at all. Are you missing the large flat washer under the basket?
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Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
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Cable does not even appear to be tight in this picture
Not sure that jerry-rig is gonna work very well
This is more like what it should look like
Are you adjusting it it here first?
[/img]
Not sure that jerry-rig is gonna work very well
This is more like what it should look like
Are you adjusting it it here first?
[/img]
Last edited by Mr. Wibbens on 02:50 pm May 19 2011, edited 1 time in total.
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On my KDX, I've never been able to have any free play at the lever whatsoever and have the clutch not slip
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Probably has more to do with your cable set up than anything
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Ok so some progress, I welded and ground a ramped profile into the actuator which is normally flat and have made a decent improvement. I think I have to go a little more to get it just right. Basically what this is doing is pushing the actuator pin more than stock. The actuator was welded like this when I got the bike and when I tried to make it look stock again I guess I buggered that profile up.
I can still stall the bike with the clutch engaged but it's much easier to keep it running with a little throttle. so i'm on my way.
I also have a new clutch cable coming this weekend.
Side note: I am looking for a good used clutch basket, and I will get a new actuator and pin when that happens, so this is a band aid fix for now.
Are all the baskets 89-06 the same?
I can still stall the bike with the clutch engaged but it's much easier to keep it running with a little throttle. so i'm on my way.
I also have a new clutch cable coming this weekend.
Side note: I am looking for a good used clutch basket, and I will get a new actuator and pin when that happens, so this is a band aid fix for now.
Are all the baskets 89-06 the same?
Fletch
89 kdx 200 with 99 rm125 forks
89 kdx 200 with 99 rm125 forks
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89-94
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Looks like they changed the design in that time period, as the later ones look beefier, what do you think of this?
http://cgi.ebay.com/ebaymotors/KDX200-K ... 5643e7265c
see the difference between that and the 89?
http://cgi.ebay.com/ebaymotors/1989-KDX ... 1e6351d4fb
http://cgi.ebay.com/ebaymotors/KDX200-K ... 5643e7265c
see the difference between that and the 89?
http://cgi.ebay.com/ebaymotors/1989-KDX ... 1e6351d4fb
Fletch
89 kdx 200 with 99 rm125 forks
89 kdx 200 with 99 rm125 forks
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Looking at Mr.Wibbens' photo's before I go out and get a basket I'll follow the cable advice and make damn sure it's dialed perfectly. I suspect I have more effective cable pull losses through the old cable setup as Wibbens suggested. I'll let you all know how it goes down this weekend
Fletch
Fletch
Fletch
89 kdx 200 with 99 rm125 forks
89 kdx 200 with 99 rm125 forks
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An H basket will mate up properly with all the gears and such, but because it's a different diameter, you need all the H plates and the H pressure plate and hub. So you'd have to get the whole assembly. And once you get the whole assembly in there, I'm not sure the E clutch cover and actuator arm would work with the H clutch.
Definitely get an E basket, 89-94.
Definitely get an E basket, 89-94.
David Eckel