PoconoPete
Member
- Jun 9, 2004
- 7
- 0
Long story but I'll try to be concise. 1997 KDX 200. B rider and D mechanic. Bike wasn't staying in gear. Kept jumping into neutral. Open her up removing only clutch cover, magneto cover, clutch basket, clutch, pusher rod etc. and I find small broken return spring in the shift assembly. The small one towards the front of bike not the scissor looking one. Got it all, two pieces, nothing else floating around. While getting in there I had mistakenly loosened the clutch spring nuts. No big deal I figure I'll just toque them back to spec which I did. I replaced the spring and put everything back together properly (I've checked and quadruple checked). Everything is back in order according to the manual. The clutch does not want to work. Pulling the lever just gave me this weird hard resistance like the push rod wasn't moving anything. I go in again and check everything again. All looks OK and button her up. This time I pull the clutch lever and it seems like no resistance at all like the clutch release shaft (the vertical rod) is not reaching or touching the the push rod. I can work it by hand and just feel the light spring tension. I open it up and try pushing hard on the push pin. Nothing moves. Should it? I then back off the spring nut bolts so they are loose (just to test) and I can now compress the spring plate. I put cover on and the clutch pull feels fine from the lever, normal, but clutch isn't disengaging the gears. I torque the spring nut bolts back up because I know they need to be bottomed out and the torque is correct. Now I'm stuck as to what to try next. Is the clutch cover very finicky to correct reassembly? I took care to have the flat side facing the push rod. This is strange because it worked fine before I took it apart. Everything is back in place. I ended up removing the clutch plates and soaking them in oil, checked the basket for wear etc. just to be sure. Torqued spring nuts to 9.3 Nm as required. Is there something in the disassembly or assembly process that I am missing (a gear turned or something not positioned right that I was to do) or is it safe to assume that you simply put it all back together as the schematic shows. I am sure that no parts, washers etc. are missing and that it is assembled correctly. Plates put back in proper order. I don't understand what I'm missing.