KDX Shifter KIPS Pin Repair 5 of 5

[@noco-adv]

The last friction plate does not go into the same notches as the rest of the friction plates in the basket. The last friction plate is the only one that goes into a separate notch right next to it which is the shorter channel in the basket. You don't have a single tang from the last friction plate in that shallow notch. This is probably why people are having trouble. The clutch hub nut is also 65 ft lbs .

[@jeffsilver4730]

Good catch, I saw the same thing.

[@TheHappycoke]

Liked so this gets seen. I double checked the manual and you are 100%correct. Thank you

[@danielpaddor3758]

I saw that as well..

[@danielpaddor3758]

Ya, the one friction plate shod be offset in the other notch in basket..

[@jroncallo]

Great info. I was looking to see which way the crown springs went. Its in this video.

[@desertbootguy]

Super helpfull. Thanks a lot mate !

[@juanmesa6348]

Cool thank you

[@Groot_G]

Thank you for the help.

[@silviowanderleimaieski]

Bom dia Shadowdev1! Qual a quantidade de óleo exata no motor/caixa da KDX 200 ano 1995/96, na tampa indica 0,70 L, no entanto coloquei 1L e ficou aparecendo muito pouco no visor da lateral! Tenho essa dúvida e você poderia me ajudar? Agradecido desde já...

[@jamesking2467]

How do you tighten everything to spec without the basket spinning?

[@BloodPshyco73]

That clutch basket, doesn't it have 2 spring rings... but one that isnt with angle? (flat)

[@pwee507]

BloodPshyco73 yeah one is flat. one is like a spring. i assume it helps to sepearte the plates

[@SMMBHQ-cg2zy]

you must torque in the future otherwise ?

[@STEVE_M439]

For the steel plates and friction plates, is there an up side or down side? Can the go either way. ?

[@davidevelyn530]

There is a smooth side a a sharper stamped steel side. They should all go the same way. The smoother side is the one that engages.

[@pwee507]

my clutch won't disengage. I have assembled this clutch 4 times the exact way you have and its just not disengaging.... frankly i dont even understand how this clutch can work. how does putting more pressure on that rod which in turn puts more pressure on the 4 springs release the hub and allow it to spin independently from the basket????

[@pwee507]

the only way that i can see that the hub will spin independently from the basket is when pressure is fully released from the 4 springs... how does puttong more pressure on them disengage the clutch it makes no sense at all. and my clutch isnt disengaging. i cant figure out why.

[@MrFireline55]

M having the same issue. My guess is the oil was too thick and cold. I live in Canada. I cleaned my plates anyhow, it's going together right now. Hopefully it'll disengage.

[@pwee507]

506 Offroadin yeah man. alberta here. i dont think its the oil for me. ive tried 3 different kinds. its a brand bew clutch completely except for the two hub washers and sleeve. also didnt replace the singular concave spring or the hub itself. all these seem to be in good shape. I cant figure out why the plates wont release.....

[@MrFireline55]

pwee507 weird man, I'm currently having issues tourqing that main nut. The 58 ft lb pound. I also tried two different oils. I'm still going with temperature though in my case. It worked fine when it was put away, I figure the oil between the plates got all gummy and caused the issues. Still chilly here in N.B

[@pwee507]

506 Offroadin fu***ing A! NB my home! careful torqying that hub nut. i didnt exactly torque that. i give it a couple shots with the impact....carefully.