Clutch

Ricky

Hi guys I'm replacing my clutch and I've had to buy a new washer that goes in between 1 of the plates I'm unsure where it goes and 1 of my plates is smaller than the others and don't know where that goes either I'm hoping someone can help thanks I've uploaded a pic of the clutch

Calum

@Ricky Check my tutorial in the Kickstart conversion bud.

The plates are also weighted and need to be balanced.

I've described this process there.

Check it out!

Ricky

Cheers mate ill have a look now

Ricky

I put it all back in and the revs still die down when I pull the clutch in and when I put it in natural the engine vibrates where the clutch is

Calum

@Ricky How bad is the vibration??

As said the clutch is weighted and needs to be balanced properly.

If the clutch is REALLY bad, then sounds like it hasn't been timed correctly with the balancer shaft.

Has the engine been rebuilt?

Remember, it is a two stroke, expect vibrations. Again it comes down to how bad.

Could be lose engine mounts...

Ricky

@Calum it only happens when I put it in natural and let my clutch out as soon as I pull my clutch in it stops but then the revs die down its only started doing this since I put the new clutch in

Calum

@Ricky And again to confirm, you definitely balanced the clutch properly as I described?

The clutch springs the old ones? Are they within tolerance? Are they torqued appropriately.

Ricky

@Calum yeah I spaced the notches out on the metal plates evenly the springs are new this is the clutch i got http://m.ebay.co.uk/itm/EBC-DRC-COMPLETE-CLUTCH-KIT-FITS-YAMAHA-DT-125-X-2005-2006-/131742599793?nav=SEARCH

Calum

@Ricky Don't really know what to suggest then.

Could be worn primary drive bearings and pulling the clutch out exacerbates things.

How many miles has the engine done, and has it ever been rebuilt?

Ricky

@Calum it's done 20k not sure when it was rebuilt

Calum

@Ricky Well if it's original internals then it could be knocking, which will mean it'll need a rebuild.

if it's been rebuilt then it could be that it hasn't been assembled properly, and the engine hasn't been timed up properly. But the vibration when the engine isn't timed up is really bad!

Ricky

@Calum it's not that bad I don't think haha but it only started since i put the new clutch in

Mightyman

2 stroke KTMs are renound for an unusual sound if you aren't holding the clutch in but what you are describing seems like more than just this..

Ricky

@Mightyman this never use to do till I changed the clutch

Calum

@Ricky Probably just paranoai. You definitely got enough oil.in there yeah.

Darty

Go back in and check the torque on the nuts, is it noisy? like a continuous ticking sound? Clutch plates are slipping if the revs are dying, Re-adjust the clutch action on the clutch itself.

Mine did this once, but vibration suggests bearing, or loose plates, which seems unlikely.

Ricky

@Calum haha something is different and yeah 750ml

Ricky

@Darty it's more like a thudding noise than a tapping

Ricky

@Darty the inner basket spins when I tighten the springs up I've got them tight

Ricky

What's the best way to put the metal plates in sharp side facing the engine or the smothered side I've been told it doesn't matter as long as there all the same way