QuestionI have a mid 90's KDX 200 2stroke dirt bike. The bike starts fine and will even run in gear when I lean it up on the stand however when I try to ride it and put it into gear and take off the bike will stall. Any ideas?
AnswerHi Andy,
It sounds like the clutch is not releasing.
This can be caused by the clutch plates
being stuck together or by a worn clutch basket.
The basket can get wear grooves in it which cause
the plates to hang up instead of separating.
If you drain the oil and pull the clutch cover
you can remove the clutch springs and
see if the plates are stuck or the
basket is worn by the plates.
If you do this be careful when tightening the
clutch spring bolts. They should be tightened
gently or they can break the clutch hub posts.
About 6 ft/lbs torque which is not much.
Check all the plates and see of they are burned or warped
by laying them on a smooth surface.
Check the hub and basket for wear grooves.
You can file these or replace the parts with new ones.
Metal plates can be sanded lightly.
Fibre plates must be replaced if worn.
Oil the plates on reassembly.
Watch that the clutch release arm on the cover
is turned properly to work ok when you put the cover
back on.
If you get the clutch working and take most of the
slack out of the cable then the clutch should release
so you can put the bike in gear without stalling.
Also make sure you are not low on fuel or have
a plugged fuel valve or carb float needle
that is sticking.
Any moisture in the carb bowl will cause stalling also.
Luck!
Wayne S.
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