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Discussion Starter #1
I have changed the clutch plates and springs on my kx80. Now, the clutch is very hard and pretty much does nothing for the operation of the bike. I was told to put some slack on the spring bolts to allow space for the pusher bearing to engage the clutch. This is not mentioned in the service manual. Does anyone have any advice on this????
 

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What clutch springs did you install? heavy duty or stock or what? I'm thinking the issue may be with the springs.


ps: leaving the clutch spring bolts slack doesn't sound like a good idea.





.....
 

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Thank you for getting back. I'm still trying to find an answer. When I tighten mine down I don't get any pull-back from the clutch handle movement. (after putting cover back on) I added a photo of the clutch spring plate that pulls the springs down to the clutch wheel posts. When I tighten that, it pulls that plate all the way to the bosses/pegs of the the clutch wheel compressing the springs and not allowing any movement for the springs to effectively do their job.

I also uploaded a picture of the springs I'm using per Martin-csr's question. The spring on the left is old and the one on right is new. (rotate pictures 90 deg clockwise in your brain. For some reason the forum view doesn't do this)

Thanks!
 

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Discussion Starter #7
So when you put everything together does the clutch still stick?? Do you have any play in the clutch lever???
 

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Sorry for the delay! I missed your response.

When I got it back together the clutch lever coming out of the crank case cover acts like there is zero resistance pushing back on it. It more or less makes sense because the clutch springs are effectively fully depressed when I tighten the spring plate down to the clutch wheel.

Otherwise it seems like I'd have to leave the bolts loose that push down the spring plate, which has me very concerned. I feel like I'm missing something basic.
 

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Discussion Starter #9
I can’t seem to figure it out either. I’ve had a couple say to leave the bolt turned out a few turns but it’ll just shake loose.
 

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So, you're where I'm at. Ok, I thought you had fixed it. Well, I'm on the hunt to resolve this, so I will post back if I can find a resolution.

Happy St. Patty's Day!
 

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Good news. I hope to have some feedback for you on that clutch. I took it to a place recommended by the local Kawasaki dealer and he figured it out. He told me on the phone all of the stuff I did wrong, but once I get a chance to see it I hope to have some feedback for you that can help you through it.
 

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Ok, I finally got a chance to open back up and document for you. (and me for later notice)

Audio isn't great, but I think this should help you. Feel free to PM me and we can talk by phone if that's helpful. Rides great right now.

There are two more videos after this as part 2 and 3.
 

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Discussion Starter #14
I did everything you did. I even tightened the spring bolts down all the way. The lever is still pulling hard. What am I doing wrong???
 

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Discussion Starter #15
I pulled out the bike and went over everything you did and copied it. I tightened the spring bolts all the way. I still don’t get any free play with the clutch.
 

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So when you put everything together does the clutch still stick?? Do you have any play in the clutch lever???
mines is having the exact same problem lever is stiff and thsres no play plus when i put it into gear nothing happens
would anyone be able to tell me what order the friction plates and steel plates go in and if theres a certain type of way they go in
 
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