Help KX125 Clutch

**LittleJohn** · 2nd June 2008, 19:39

Help please, I have just rebuilt the bottom end of my 1999 kx125 and now the clutch is not engaging. It has a new clutch hub, I got rid of the grooves on the clutch basket and de-glazed the clutch plates but it still doesn't work.

I have been tightening the clutch nut with a torgue wrench to the specified Nm but as I don't have a clutch holder I have to use a socket on the drive shaft tied to the frame...... so may not be to the correct toruge setting. The clutch hub does move freely in the clutch basket with no plates in there.

Also measured the springs and they seem to be longer (by about 1 - 1.5mm) than that specified in the service maunal. Not sure if this could cause the problem.

Upon fully tightening the pressure plate (to appropriate Nm) the clutch doesn't engage, but it seems like all of the plates are sticking together a bit. Have even put everything back together and run the bike for a few minutes, then tried the clutch and nothing, the back wheel just spins, no matter what gear. If you put the back brake on the bike will just stall.

Any thoughts on what it is????? Please help, sick of pulling it to bits and putting it back together just to find out there has been no change.

**cheese** · 2nd June 2008, 20:53

There is a rod that pushes teh hub out to let the plates seperate, Id say this could be worn? I've only pulled appart a RM250 one so I'm not too sure about the KX.

If you pull teh clutch in does it push the part holding teh plates out?

Longer springs - should be ok, just stiffer clutch.

**LittleJohn** · 2nd June 2008, 21:14

Yeah it pushes the pressure plate out a few mm's, looks like a big enough gap but maybe will measure it and see if I can find some specs for it.

Thats what I thought about the longer springs......

**barty5** · 2nd June 2008, 22:33

Originally Posted by LittleJohn

Yeah it pushes the pressure plate out a few mm's, looks like a big enough gap but maybe will measure it and see if I can find some specs for it.

Thats what I thought about the longer springs......

did you oil the plates as you put them back in the basket??
the springs will shrink as they weakin with age.

**theblacksmith** · 2nd June 2008, 22:49

Have to agree with Barty - oil them with the most slippery shit you can find. Try loosening the bolts just to get them slipping and then re-tighten.Take up any free play so you can get max travel on p/plate.Keep us posted.

**LittleJohn** · 3rd June 2008, 18:50

I oiled all of the plates when installing them, using Bel Ray gear saver oil, supposable good stuff. Have just restripped everything, going to deglaze again, then put everything back together in the hope that it works. Talked to my mechanic and he reckons the clutch nut is to tight so will try it a bit looser and see. Theanks for the tips, better get back out to the garage and see if anything will work.

**LittleJohn** · 3rd June 2008, 20:29

stripped down again, deglazed, soaked in oil, put back in, all parts there according to the diagram on kawasaki website still didn't work. Adjusted clutch nut starting from finger tight thru to as tight as air gun would get it, trying clutch at different tighnesses & pressure plate tighnesses still nothing. Have noticed pressure plate moves out but the plates seem to be stuck together. Not sure if this bel-ray oil is the problem but its in the manual as transmission oil to use

Now at a loss. Heading away nxt wk for a few weeks so maybe bike will have to wait to go to mechanic when I get back.

Still open for ideas in the meantime so I can fix it.

**4stroke** · 3rd June 2008, 20:42

i assume therod is moving through the centre of the clutch, does the clutch lever feel like it has weight on it, like it used to before you dissasembled?
im unsure on the kwakas, but the hondas have a needle face roller bearing that gets pushed by the push rod which pushes the clutch cover out-ward.

**LittleJohn** · 3rd June 2008, 20:57

Yeah the Kawasaki has a bearing at the end of the push rod attached to the pressure plate which is all there. Clutch lever has no slack in it & plenty of pressure behind it. Pressure plate moves in & out fine with enough gap out when clutch lever is pulled in

**4stroke** · 3rd June 2008, 21:03

hmmmm, the plates arent tight on the outside of the clutch basket, arround the circumfrance of the plate? did you put new steel plates in with the fibre plates?

**LittleJohn** · 3rd June 2008, 21:18

Only new part of the clutch was the clutch hub. Clutch basket has been degrooved (grooves from friction plates) plenty of room for friction & steel plates. The pressure plate engages onto the friction plates nicely when clutch is out & obviously comes off the plates when clutch lever pulled in

**barty5** · 3rd June 2008, 23:39

Originally Posted by LittleJohn

Only new part of the clutch was the clutch hub. Clutch basket has been degrooved (grooves from friction plates) plenty of room for friction & steel plates. The pressure plate engages onto the friction plates nicely when clutch is out & obviously comes off the plates when clutch lever pulled in

you got the plates in the right order fiber 1st then steel etc etc should finish with fiber as well?
also looking at parts diagram there is a washer between the housing and the hub the plates sit on.