Planet Minis

EricM22

First post here, hi all.

Just added a manual cable clutch kit (Ebay) to my 10 year old son's KLX110. It is now a dedicated manual trans, I used the primary gear conversion washer, removed all of the heavy parts as per the instructions. It is otherwise a stock engine.

The bike runs fine after the surgery, but there are a few quirks that I don't know if they are normal or not, perhaps someone here can help.

1. Will start only in neutral (of course) but only when the clutch is NOT pulled in. When you pull in the clutch lever, the kick start spins freely and does not engage. Is this normal?

2. There is a slight whine in the front of the engine case that wasn't there before. That I can understand, but when downshifting and letting the trans "drag" down the speed - not over-revving, though - there is an almost mechanical knocking/rattling sound, doesn't sound normal at all. The sound goes away instantly when the clutch lever is pulled in. Doesn't seem to affect performance, but the sound is troubling to me. Is this normal, is it a result of keeping the original primary drive and its slipping, or did I do something wrong with the install.

Anyone else who did this procedure, please let me know what your experiences were with the above. Thanks.

Pimpindahoes

1 = normal. clutch is on the primaries.

2 = normal with stock clutch.

Pimpindahoes

oh i forgot.....

WELCOME!!!!

EricM22

Will the knocking/rattling sound when downshifting go away if I replace the original primary having the conversion washer with a dedicated manual primary instead? I'd really like to get rid of that metallic rattling sound.

Pimpindahoes

now that i read that again, i dont think #2 is normal.....but people and vendors have said otherwise.

but i was refering more to a whine. didnt really read it right i guess.

knocking and rattling isnt good. i would take it apart inspect everything and then put it back together making sure that you do everythign right.

bt260

#1 is normal
#2 doesn't sound normal. If/when you switch to a primary drive gear instead of the spacer washer, you'll get a whining noise depending on which gear you use. The Takegawa gears are quiet, but the Cold Fusion and some others are noisy. The rattling or knocking doesn't sound right. I'd pull the cover and check to make sure the removal washer is properly seated in the clutch hub.

2kawiracers

if it is the cold fusion primary gear that is the whining noise i changed to the takegawa and no more noise hope this helps

Lev

Did i get it all wrong when someone told me that you don`t need to use removal washer if you install primary gear drive???

bonez1093

thats right you dont need the washer only with the stock one