Motorcycle Repair: 1981 KDX 175 Clutch, clutch basket, yamaha bw200


Question
I am rebuilding/restoring a 1981 KDX 175.  I am reassembling the bike now.  I have reattached the clutch cable from the bottom end first, then at the lever.  At first, the clutch was "immovable." When squeezed, the clutch didn't move. So I took it apart again to check the bolts, clutch plates and springs.  The bolts were bottomed out, the plates were locked together, and the springs totally compressed.  I took the clutch basket apart and freed the plates. (They are still thick enough to use)

One thing I noticed, though.  The clutch basket has some grooves where the plates made contact.  Will that keep my clutch from working?  Can I file the grooving down until I get a new clutch?  Could the springs be too tight?  My clutch on my Yamaha BW200 is so much easier to squeeze/use. Is i possible to have too tight of springs?

Thanks,
Mike

Answer
mike you can file down the grooves but when you do that you give the plates more room to move and that will cause the plates to break.When you hit the gas the plates use one side of the basket and when you hit the brakes the plates will use the other side.thats why you cant file the inner and outer basket.Well i shouldnt say that you cant as long as they are not too bad and there is enough ratchetingbetween the plate and hub, but my suggestion is to bite the bullet and buy a new basket and never worry about it again.I am glad that i could help.