Question about 1998 kawasaki KDX 200

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How to remove the clutch from my kdx 200

Hi guys

I have to replace the spring behind my kickstart gear as it keeps on slipping. However to get to the kickstart gear i need to remove the clutch. Another problem arises. Once i have removed the 5 spring bolts in the clutch i come to the hub nut which is holding the pressure plate on. This hub nut is being a pain in the arse. I dont own a rattle gun so that option is ruled out. But if anyone knows what tool i can use to hold the clutch, to loosen the hub nut, please let me know

thanks
andy

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  • Anonymous Mar 24, 2014

    I can't seem to loosen the nut that holds the front sprocket on my KLR650.Is there a trick or do I just reef harder?I'm afraid I am going to break something.

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  • kawasaki Master
  • 2,050 Answers

The simple way to do it is borrow an electric impact gun. (1/2" drive) If you jam something in there you can damage things.

Posted on Jul 28, 2009

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My bike stood for 5 months. it goes into but doesnt move in any gear


Hi, Alan for more information about your question and valuable free downloads that you will need please visit the websites below. Good luck and have a nice day.
https://www.tradebit.com/filedetail.php/153680930-kawasaki-kdx200-kdx220-service-manual-repair
http://www.faqs.org/qa/qa-3990.html
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One test is with engine off, pull in clutch and cycle kickstarter a few times.

There should be drag for the first 2-3 kicks, then it should free up (the clutch plates tend to "weld up" [just a term] from heat wile running).

If not remove primary cover.

Pull in clutch lever, cycle kickstarter, and watch that pressure plate isn't "wobbling" as it turns.
If it does, you'll have to tighten 1 or 2 of the 3 clutch spring nuts to get it to turn true.

Then adjust the clutch pushrod free play.
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Adjust the clutch cable so there's about 1/16" to 1/8" slack at the lever end.

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The clutch in your bike is a wet clutch. There is a lot of hyrdostatic friction even when the clutch is released completely. I think a large factor is the type, age and condition of oil. Perhaps something as simple as an oil change would help.

Jan 14, 2010 | 2005 kawasaki KDX 200

1 Answer

2005 kdx 200 clutch not engaging properly


Assuming the clutch handle on the handlebar is adjusted properly, only three things will cause the problem.
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  • Worn clutch lever (at gearbox). Lever is not moving the pusher far enough to fully disengage the clutch. A new lever would be needed.
  • Synthetic lubricant ( or oils with "special" additives), was put in gearbox. 10w40 motor oil should be used in the gearbox. Synthetics can swell the cork on the friction plates causing the clutch to drag. New friction plates will fix the problem.
The current amount of clutch drag is not enough to harness the power of an engine rev. That is why the clutch seems okay at higher revs. Please rate my answer. Thanks.

Jan 14, 2010 | 2005 kawasaki KDX 200

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My 125dt dosent sart or kick sart,the gear inside have a bushing in shafting?or it was broken..


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The clutch's plates must be stuck.Disassemble them and renew if necessary.The clutch lever should have 3mm freeplay and the spring's bolts should be tighten at 14Nm.

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1 Answer

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I did an internet search to see if this was a common problem for the KDX but couldn't find anything. You might try going to the "Thumper Talk" website (http://www.thumpertalk.com/). You might find someone who has specific knowledge your particular bike and this repair.

I had a similar problem with my Harley, it turned out the kicker gears were worn out. Pull the clutch cover and carefully inspect the kicker gears. If there are any unusual wear patterns replace both of them along with the cracked clutch cover. If you don't already have a repair manual specifically for this bike get one now. It will make repairs much easier.

Good luck!

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