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    • Ricky
      Ricky last edited by 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 0_1485103503757_20170117_160845.jpg

      Calum 1 Reply Last reply Reply Quote 0
      • Calum
        Calum @Ricky last edited by

        @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!

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        • Ricky
          Ricky last edited by

          Cheers mate ill have a look now

          1 Reply Last reply Reply Quote 0
          • Ricky
            Ricky last edited by

            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 1 Reply Last reply Reply Quote 0
            • Calum
              Calum @Ricky last edited by

              @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 1 Reply Last reply Reply Quote 0
              • Ricky
                Ricky @Calum last edited by

                @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 1 Reply Last reply Reply Quote 0
                • Calum
                  Calum @Ricky last edited by

                  @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 1 Reply Last reply Reply Quote 0
                  • Ricky
                    Ricky @Calum last edited by

                    @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 1 Reply Last reply Reply Quote 0
                    • Calum
                      Calum @Ricky last edited by

                      @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 1 Reply Last reply Reply Quote 0
                      • Ricky
                        Ricky @Calum last edited by

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

                        Calum 1 Reply Last reply Reply Quote 0
                        • Calum
                          Calum @Ricky last edited by

                          @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 1 Reply Last reply Reply Quote 0
                          • Ricky
                            Ricky @Calum last edited by

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

                            1 Reply Last reply Reply Quote 0
                            • Mightyman
                              Mightyman Global Moderator last edited by

                              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 1 Reply Last reply Reply Quote 0
                              • Ricky
                                Ricky @Mightyman last edited by

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

                                Calum 1 Reply Last reply Reply Quote 0
                                • Calum
                                  Calum @Ricky last edited by

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

                                  Ricky 1 Reply Last reply Reply Quote 0
                                  • Darty
                                    Darty last edited by

                                    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 2 Replies Last reply Reply Quote 1
                                    • Ricky
                                      Ricky @Calum last edited by

                                      @Calum haha something is different and yeah 750ml

                                      1 Reply Last reply Reply Quote 0
                                      • Ricky
                                        Ricky @Darty last edited by

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

                                        1 Reply Last reply Reply Quote 0
                                        • Ricky
                                          Ricky @Darty last edited by

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

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                                          • Ricky
                                            Ricky last edited by 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

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