KDX200 Clutch

[PZR]

Another question about the old mid 80s air cooled KDX200 I have done up. I have now got it going and a friend and I took it out Sunday and had a play. Great fun for a first time newbee. The only two problems I have are
1/ The kickstart lever is so old and flogged out it ineeds replacing so if anyone has a good one going cheap I am interested please. A new one is half the price of what I paid for the bike so I am not going there.
2/ The clutch will not disengage properly. If its cold and I drop it into gear it will stall the engine, but once it gets warm it will still stall if the revs are not kept up.
I adjusted it the cable to various positions which did not make any real difference. I have not checked the friction and steel thicknesses as I do not have any measurements but the eyeballchrometer says they look reasonable. It is not slipping at all. Basket is not worn. Oil is new Motul 2 stroke mineral gear oil. It was missing a spacer washer between the release bearing and the pushrod (92022B in the attached picture) so I made one and fitted it back together with a new (home made) gasket. I made the gasket out of thin gasket paper thinking it would help give more clearance, by bringing the outer case/pushrod closer to the clutch pack giving it more push, but I still do not seem to have enough push to release it completly. Remember this is an early type clutch release which pushes from the outside of the clutch pack not like the later ones which push through the centre from the left side of the bike. Any thoughts anyone. I did wonder if the oil is causing drag as it makes a big difference when it warms up, but I am unsure about that.

[PZR]

Sorry, I cannot seem to add the picture
Oh by the way F5 and TWR thanks for your help the other day. It turned out the problem was a tear in the carb inlet mount rubber so it was never going to start with all that extra air. But it goes great now.

[T.W.R]

One of the other Mechs at work just did a rebuild on an 88 model with the same symptoms I'll check to see what he did & let you know.

mmm the kick start, worn on the spline?

[F5 Dave]

I assume you mean the knuckle to lever is worn (rather than the knuckle grabbing the spline).

This makes the kickstarter lever sloppy, folds out when it shouldn’t & folds past 90deg.

You can build the knuckle or lever up with mig-weld & grind it so it doesn’t bend part 90.

You can pull it apart & build it up a bit with braze & I seem to remember preloading the spring so the ball-bearing that rolls into the detent pushes harder so it stays folded in. Disassemble over clear well-light ground. That bb & spring will bid an escape.

clutch:
I always used motul in my 91 with no symptoms thus.
You could pack in another steel plate to space the pack out. If the cable has stretched then the lever has to be adjusted to pull at the end of its travel. You could put a specially made washer behind the bearing to space it out. Did so in some Honda clutches but I think the kdx one would respond the same & still be retained.

I made my engine clutch actuator lever longer to make the pull lighter (also braze to repair seal surface), but it means it pulls less distance, even so it never dragged when starting in gear. Maybe a tickle when cold, but never to stall.

[PZR]

Thanks for the advise guys I will do some more checking this weekend
PZR

[cheese]

the clutch issue is more than likely to be a worn basket, it you have a look is there grooves where the plates sit in the basket, it can catch the plates and the doesn't disengage properly.

[F5 Dave]

. . . Basket is not worn. . .

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