Help KX125 Clutch

[cheese]

have you got a steel ruler? use the side of it to see if they are all not bent. To be honnest there is not much else I could think of that would cause the problems...

Where in Auckland are you?

[LittleJohn]

Hadn't thought of using steel ruler so will check tonight if any are warped.
I'm on the Shore near Hauraki Corner.

Just found out this arvo a stupid truck driver has taken down our phone line today which can't be fixed til tomorrow so will have no internet tonight

[4stroke]

does the hub look the same as the old one, obviously you changed it as it was worn or brocken but it could be machined wrong, or posibly the wrong part.

[theblacksmith]

What a mind boggler! Makes me wanna come up and investigate- curiosity killed the clutch!

[4stroke]

What a mind boggler! Makes me wanna come up and investigate- curiosity killed the clutch!

yeah i was thinking that before.

[cheese]

Should we all head over for a beer and ponder over it?

[Buddy L]

ill be their, maybe only good for a laugh and to help drink.

[vr4king]

Hmm does it cycle through the gears ok and can you find netural?.............Im thinking theres some cog on cog action that shouldn't be happening

Hows the kickstart feeling?
Can you hit netural with the clutch cover off and crank it over using the crank end without the back wheel turning or vise versa spin the wheel and see if it rotates the engine?
It really must be something else if the clutch lever is lifting the centre hub or you got to many plates in there but that seems impossible unless the new centre is different

Please inform us when you do find the culprit cause now im curious

[4stroke]

im picking that its gota be something thats been changed, if hes only changed the clutch hub, there must be a descepancy in the hub or an assembely error.

[LittleJohn]

Thanks guys for all the replies. Finished work late yesterday & couldn't be arsed pulling it to bits yet again. so am thinking i will tonight. hopefully our internet will be back on by tonight & i will get back on & do some replies.

[LittleJohn]

does the hub look the same as the old one, obviously you changed it as it was worn or brocken but it could be machined wrong, or posibly the wrong part.

Compared the new one with the old one, both exactly the same. Also it is a geniune Kawasaki hub.

[barty5]

If You Want Feel Free To Bring It In To Work Shop It In Newmarket Happy To Help Out Have A Look One Evening Lots A Beer In Fridge Sure If The Cheese And The Rest Come Down We Could Figure It Out Im Here Late Most Night Got Home Last Night Just After 12 (moral To That Is Dont Do Engine Transplants On Vectras)

[LittleJohn]

Hmm does it cycle through the gears ok and can you find netural?.............Im thinking theres some cog on cog action that shouldn't be happening

Hows the kickstart feeling?
Can you hit netural with the clutch cover off and crank it over using the crank end without the back wheel turning or vise versa spin the wheel and see if it rotates the engine?
It really must be something else if the clutch lever is lifting the centre hub or you got to many plates in there but that seems impossible unless the new centre is different

Please inform us when you do find the culprit cause now im curious

It goes through all of the gears no problem (apart from obviously no clutch working), can get into netural, bike starts sweet as in neutral, can then put into gear, go through them but when pull clutch in the wheel keeps spinning. Cannot use kickstart when bike is in gear but when it is in neutral, no problems. Bike free-wheels nicely in Neutral as well.

If I have the cover off and wheel the bike forwards the, pull the clutch in and put it in gear it is very difficult to keep going forwards and will slowly turn the engine over. The plates don't split what so-ever, but if you put your finger in and manually do it they move. Seems like they are stuck together a bit!!!!

As far as the clutch goes only the hub was changed. The bottom end has had a new crank, bearings and seals.

[LittleJohn]

If You Want Feel Free To Bring It In To Work Shop It In Newmarket Happy To Help Out Have A Look One Evening Lots A Beer In Fridge Sure If The Cheese And The Rest Come Down We Could Figure It Out Im Here Late Most Night Got Home Last Night Just After 12 (moral To That Is Dont Do Engine Transplants On Vectras)

Cheers, am heading away on Monday for 3 weeks, if I don't get it in the weekend I might have to take you up on that offer......

[LittleJohn]

Just come in from the garage for some dinner, missus made me, I have re-stripped the clutch (and all parts were there and in the right order), cleaned and dried everything. Have checked for warpage and thicknesses of both clutch plates and friction pates. All are good and within service limits.

The friction plates have clearance inside the housing and can freely move within it. There is no damage to the friction plate tangs or to the clutch plate teeth.

Am still at a loss. And now the clutch cover gasket is stuffed!!!!!!!