clutch assembly

[builtogo]

The clutch lever doesn't feel right on a '98 kdx 220, after taking off the clutch to fix a shifter shaft problem. The pull is much harder than before and there isn't the usual feel of disengagement. I've checked the shop manual assembly diagrams again and again, there's no missing or leftover parts and I can't figure out what's wrong. Any ideas??

 

[builtogo]

You dummy!

After you solved the shifter shaft problem and you had the clutch assembly in your hand and were trying to figure out how it worked, the thrust washer that separates the clutch housing from the plate holder slipped out of place. So when you put it back together it jammed and resulted in a strange feeling clutch lever. Next time, separate the two assemblies and install them one at a time, with the thrust washer between them and fixed on the transmission input shaft. And don't drink so much beer after you take things apart, it affects your memory.

 

[tommrth]

haha i do stuff like that all the time and i always have bits left over