Question about 1998 kawasaki KDX 200

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How tight should clutch basket bolts be,do you just screw them all the way down?

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If you mean the bolts that hold the clutch plate in the basket??...then bolts should be done down all the way!!

Posted on Apr 12, 2010

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Hi, Jason and the usual suspects are:
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Hi Anonymous I am sorry you can't find the first and best tool you ever bought for your Aprilia but despair not for a mere $10 you can download another one. For more information about your issue, please visit the websites below. Good luck and have a nice day.
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To replace the clutch discs in your clutch pack, first disconnect the battery and drain the oil from the primary case. Remove the primary case. Take the circlip in the middle of the clutch assembly out and remove the clutch adjuster plate. Then loosen and remove the bolts that hold the clutch together. Loosen them all and take them out evenly loosening each bolt one or two turns at a time so as not to warp the clutch spring. Once you get this off, you can remove the spring and the clutch plates. As you take the individual parts out, notice the sequence that they are installed in the clutch basket. When you replace the parts you wish to replace, make sure you get everything back in the proper order. Put a little Loctite 242 med. blue on each of the bolts that hold the spring plate on. Replace the clutch adjuster plate and circlip. Replace the primary cover and fill with oil up to the bottom edge of the outer clutch basket with the bike standing straight up. Do not overfill or your clutch will drag. Adjust the clutch according to the manual.

To adjust the clutch, find the clutch cable adjuster in the middle of the clutch cable. Slide the protective boot up or down and loosen the lock nut. Turn the adjuster barrel inwards to get as much slack as you can get.

Remove the derby if you don't have it off. Loosen the lock nut on the adjuster screw in the middle of the clutch assembly. Back the center screw up until it's completely free and then turn it back in until you feel a resistance. DO NOT FORCE THE SCREW. It will break the inner clutch hub if you force it. If necessary, perform this several times to get the "feel" of what you're doing. Once you feel the resistance, stop, then back off 1/2 turn. Tighten the lock nut down.

Then go back to the cable adjuster and turn the adjuster barrel out until you've got about an 1/8 freeplay in the cable. Squeeze the clutch a few times and recheck the freeplay. Tighten the lock nut and replace the rubber boot.

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3. With a brass/aluminum/soft iron punch or drift firmly planted on the head of the screw/bolt smack it hard 3 times with a hammer.
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For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a nice day.
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1 Answer

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The whole basket isn't all that great to take off....but if you are just changing the clutch plates, you won't need to remove the basket. There will be an outside pressure plate holding them all in there, usually 5 bolts hold that down (those 5 bolts also have the clutch springs under them) Pull that off, and inside there will be the part that your clutch pushrod moves to release tension on the plates (sorry forgot the name of it right now) make sure that when that comes off, that you don't lose the ball bearing behind it. Goodluck.

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1 Answer

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1) Release the pressure on the system by unhooking the clutch handle from the cable
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4) Remove the kick starter by removing the bolt holding the lever onto the starter shaft. Carefully, maybe with a impact driver screwdriver, loosen and remove the screws holding the round clutch cover from the engine crankcase. There are probably five, maybe seven, Phillips screwheads or maybe with ten mm hex heads. They will be different lengths so remember which holes each came from. I always replace screws with hex head bolts 'cause the screws can be a pain to remove.
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8) Put the cover back, usually using a new gasket, or at least silicone. Leaks here make a mess and it's worth taking time to get it sealed.
9) Fill with amount of oil specified on the side of the crankcase. Make sure you use 'cycle oil, with MA rating. Auto oils will allow the clutch to slip, and make it burnout quicker.

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1 Answer

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are you shure you have ALL the clutch plates?? the cable is well lubed? the pushrodbearing/adjuster may be in the middle of the clutch basket cover plate. OR you have the wrong springs installed!

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1 Answer

91 kx 250 clutch too tight


hi m8,, wen u put spring bolts and springs on,, u must do them right up ,, untill the spring is completly comprest,, ,untill the spring bolt wont do up any more,,cheers

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