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
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Clutch might be good, but it could be out of adjustment.
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.
In the center of clutch pressure plate, loosen lock nut and back off adjuster screw.
Tighten screw until it you fell it just "touch" the push rod behind it.
Back off the screw 1/4 to 1/2, hold it from turning, and lock down the lock nut.
Adjust the clutch cable so there's about 1/16" to 1/8" slack at the lever end.
Hi, easy job, if your bike is waer cooled, you dont say how old it is the old bikes were air cooled, undo all the water pipes attached to the r/h case all the water will escape, you can leave the oil inside the gearbox, if you lay the bike on its left hand side, lift the engine and block it up to make sure gear lever is not resting on the ground, as this will disengage when you remove the clutch cover on the r/hand side, undo all the fixing screws from the cover remove kickstart lever, tap the cover gently to loosen the cover and remove when loose, if the case will not come off check further for screws, sometimes hide inside water pumps etc, once you are ready to remove the cover, keep the kickstart shaft pushed inermost so that it stays located within the engine, once ready fully observe the location of spring mountins within the engine and replace the spring
Hi, i am sorry but you dont say what the model of your machine is, this would help me determing the correct, answers for your questions, most kickstart springs can be changed by simply removing the clutch cover followed by the kickstarter shaft and then replacing the spring, make a note of kickstart stop location carefully remove the shaft holding the gears together replace the spring followed by the. Replacing the shaft and tensioning the spring before cover replacment, oil,etc. Some machines the shaft and spring is inside the centre cases and a complete engine strip is ness
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.
Assuming the clutch handle on the handlebar is adjusted properly, only three things will cause the problem.
Very dirty oil in the gearbox. The grit is causing the clutch to drag. Change oil, ride for an hour in the city then change oil again to flush out the grit.
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.
Common cause of kickstarter not engaging(I am guesing that this is your problem) is a broken spring on the kickstart mechanism,or that the kickstart idler gear cerclip has fallen off(this allows the idler gear to move forward on the shaft & thus won't allow the kickstart gear to transfer drive to the clutch hub).Remove clutch cover, put kickstart lever back on shaft spline,activate kickstart lever by hand(easier with sparkplug removed+in neautral)as kickstart lever moves down 90 degrees the gear on the kickstarter mechanism should move out to engage with gear next to it(kickstart idler gear).If the gear on the kickstarter mechanism dosn't move outward it has a broken spring on the kickstart mechanism.replace spring and all should work.(if the spring is broken you need to try find the broken piece with a magnetic pick-up tool as the broken part can cause further damage if not removed)To do this job I highly recommend you first purchase a workshop manual which will guide you through these processes.After all a manual is the most valuable tool in your tool kit.
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.