I bought a 2007 KLX with the 351 kit about a year ago. It had about 7,000 miles at the time and worked great, now I have about 8,500 on it and the clutch started slipping pretty badly (really quickly too, it went from a VERY slight slip to being unable to ride it within a week). I replaced the springs with the stiffer Barnett springs but that didn't help, so I just ordered the EBC plates a few days ago and want to put them on tonight.

So I have two questions...first one is super easy:

1) What size socket do I need for the nut holding the clutch basket in place? My largest socket is a 19mm and I didn't want to go buy a new set if I could just get the specific socket I need.

2) Has anyone else had a clutch go out this quickly? I don't know how the bike was ridden the first several years, but I didn't wheelie it (often) or do anything super crazy. Do they go out quicker after the 351 is installed?

 

I had 12k on my bike, put in the big bore and the clutch was slipping like a ****, barnette springs didnt help much, ebc dirt racer did the trick.

1) I don't remember the size, I think its the 1 1/4" equivalent? 24mm?

2) yes

 

It ended up being a 22mm socket. Now if I could only figure out how to get the clutch out. I guess I'll have to do the penny in the gears trick to pervent it from spinning because my rear sprocket doesn't have any holes I can stick a metal rod through.

 

I had my bike in 6th gear had my brother STAND on the rear brake and i used a breaker bar ad held pressure about 10 times before it finally broke loose

 

Well I'm done. After trying the metal bar through the rear sprocket and having it break in half, and then while holding a penny looking for the gear needed to stick it in I (like the biggest idiot in the world) dropped it into the engine case through the gap above where a kickstarter would go. I tried everything to get it out and can't get it, and I still can't get the stupid nut to budge. So it looks like I'll be calling a local shop tomorrow and ask them to come pick it up so that I can pay them to get the stupid penny out, change the clutch plates, and put everything back together for me.

I've done all the work on my BMW R1150R for years and never had a problem like this...this KLX is killing me though.

Update: Just got worse, while putting everything back together so I could trailer it to the shop...one of the bolts that holds the clutch springs in place broke in half.