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  #1  
Old 08-15-2011, 11:25 AM
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Default 91 kx 125 clutch problems?????

I bought a 1991 kx 125 today and the clutch works fine when riding but when I start it in neutral and put it into first gear with the clutch fully engaged it wants to go. I tightened the cable at the lever but had no luck. Also read it needed to warm up good before riding and did that with no luck. Please help!!! New clutch needed????
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Old 08-16-2011, 11:27 AM
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Default Maybe

Either you have some clutch plates stuck together , you have an incorrect oil in the trans or you have notches in your clutch basket. Any of these can cause this problem.

One long shot is that the cable may be bad.

Paw Paw
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Old 08-17-2011, 01:44 PM
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Well I changed the oil today with no luck. I appreciate the advice. Next step is to clean the clutch plates. Will I need a puller when I'm in there for anything? What about the torque setting on the main nut?
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Old 08-17-2011, 09:05 PM
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You will not need a special wrench for this. Just drain fluids, pull the side cover, pull the clutch pressureplate bolts and springs ( 6 of each), then pull the plates out. Make sure not to misplace any parts!
Be sure to notice the order they came out and put them back in the same way.

Paw Paw
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Old 08-18-2011, 03:45 AM
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You cant go wrong with what paw paw said. I did it to my fiance kx125 04 and now no problems at all
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Old 08-18-2011, 11:26 AM
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Well I'm stuck like a lot of people with no air compressor or impact wrench. I do notice some notches in the basket. If I need to replace the basket is it best to just replace the plates and everything as well? Searching for a compressor and impact now, I'll keep you all posted. Thanks for the help.

Last edited by ahhforille; 08-18-2011 at 11:29 AM. Reason: wanted to post link but cant yet.
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Old 08-18-2011, 04:27 PM
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Decided to clean the clutch plates the best I could without taking the main nut off. Used the better part of a quart of 1040, cleaned really well, then reassembled. Made about 20% improvement. I need to replace clutch parts I've decided due to the amount of notches in clutch basket and plates. I know I need a new basket. EBay $170. What else do I need? Drive plates and friction plates and springs? What material should I get? I hear of kevlar, cork, and other various materials. I definitely want to upgrade from OEM. Any suggestions?
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Old 08-18-2011, 06:40 PM
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Default Why?

Quote:
Originally Posted by ahhforille View Post
Decided to clean the clutch plates the best I could without taking the main nut off. Used the better part of a quart of 1040, cleaned really well, then reassembled. Made about 20% improvement. I need to replace clutch parts I've decided due to the amount of notches in clutch basket and plates. I know I need a new basket. EBay $170. What else do I need? Drive plates and friction plates and springs? What material should I get? I hear of kevlar, cork, and other various materials. I definitely want to upgrade from OEM. Any suggestions?
Why pay more for other clutches when the OEM is very, very good stuff?
Pick up plates, fibers and springs.

RE: Basket....Hanson if you can find one.

RE: Special tools....None needed. Use hammer or other object to block the back wheel with the swingarm ( with the bike in gear) and the nut will come off with a good socket wrench. Hammer on other side of swing arm to reinstall nut.

I am not sure WD 40 is the best thing to clean the clutch plates with. I think break cleaner does a better job, but my first choice is Super Clean.

Good Luck!

Paw Paw
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Old 08-18-2011, 08:56 PM
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I think Paw means Hinson basket. Also you don't need to drain the fluid if you just replaced it. Just tip the bike on it's left side. If you are gunna replace the plates the OEM clutch is the best clutch money can buy.
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Old 08-18-2011, 09:16 PM
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Thanks you all. Are fibers seperate? I thought they were attached to the plates.
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Old 08-18-2011, 10:28 PM
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Default Yes!

Quote:
Originally Posted by ahhforille View Post
Thanks you all. Are fibers seperate? I thought they were attached to the plates.
There are two different sets of plates in your clutch. One is the fibers and the others will in most cases be steel ( but could be aluminum). They alternate in order upon installing. You start with the fiber then the steel and repeat untill all of both sets of plates have been used. The quantity may very by make, but in most cases there should be about 7 steels and 8 fibers.

You were told correct that you may be able to change them by putting the bike on it's side and not draining the fluid.

Hinson is the correct name of the maker of the clutch basket.

Paw Paw
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Old 08-18-2011, 11:32 PM
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Thank you so much. You've been a tremendous help. Here's a link to pictures of my beat up clutch. [Only registered and activated users can see links. ] Found parts on eBay and will be ordering within a day. Might be a little while but I'll let you know when it's done! Thanks again.
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Old 08-19-2011, 04:55 AM
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Default Toast!

Quote:
Originally Posted by ahhforille View Post
Thank you so much. You've been a tremendous help. Here's a link to pictures of my beat up clutch. [Only registered and activated users can see links. ] Found parts on eBay and will be ordering within a day. Might be a little while but I'll let you know when it's done! Thanks again.
Yes, the clutch basket and fibers are toast! Can't see the steels, but would suggest they are also toast!

Paw Paw
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Old 08-19-2011, 01:00 PM
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Thanks. I ordered a basket last night and found some good prices on plates, fibers and springs. I was wondering if the clutch from an H1/H2 would be the same as a regular 1990 kx 125 because one of the kits has a good price but is for an H1/H2.
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Old 08-19-2011, 01:26 PM
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Default ????

I don't know the answer to that one, but if it does not fit even "free" would be too much!

Paw Paw
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