Hi guys. first time replacing a clutch and im having problems. I followed manual, "how to Vids" and red countless threads. I took out stock plates and springs and replaced them EBC plates and Barnett springs.

My Problem is the clutch cover wont fit back on its about 1/8 inch to far from going back together. Ive taken apard and reassembled probly 6 times going back to the manual and cannot figure it out. Please help if anyone has ideas or experiance with this set up.

 

Bump!

 

Make sure the clutch release shaft is Aligned right or its the spring plate too far out...

 

Ok I can get the cover on now but when I pull in the clutch after its all buttoned up. The clutch won't engage. I can feel the tension and cable play is good and I see the shaft arm move. It feels right but holding in clutch and trying to roll while in gear is unsuccessful

 

I notice that with my Ebc dirt clutch. After the first ride its fine.

 

So your saying fill up oil and start engine and it will work? Right now it seems the clutch dosent work at all. It feels right but can't free up the bike

 

That didn't work. I filled up oil and started engine hoping warm oil would let the plates play but there was a small buzz. So i shut down. Cannot figure it out I followed the exploded diagram and manual

 

Sounds almost like an extra plate was installed. Judder spring &seat installed/centered? Use the one special plate with the judder spring? I layed the klx on its side to replace the assembly making alignment easier.

 

I took a fresh approach this am after a cup of coffee and I was reading the diagram wrong 1 putting the washer that goes on the inside of the clutch basket in the wrong place. I didn't install Judder springs since i've heard and read you don't need them with aftermarket plates and springs. Everything feels good and a quick scoot up my block checked out. Im gonna go on a longer ride this afternoon to make sure its fine.

I know some have installed EBC plates and Barnett springs with judder stock plate in place, but anyone without? any problems or damage this could cause?

Thanks again for the help guys. I was trying to get it together to go on a ride with ITNANTI this am. Hopefully he will post some pictures later on.

 

Good deal. So how many miles did you get out of the old clutch?