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BBR clutch spring install

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braaap11889

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Discussion starter · #1 ·
Alright so I installed the bbr HD clutch springs on my bike its a 2007 klx 110 with 143cc kitaco kit with 26mm carb takegawa race cam and m-6 exhaust.

They don't come with installation instructions. I put all 6 in tightened it down as tight as it would go.



I thought I had the bike in neutral when I finished installing them but looks like it was in gear. Now It won't change gears. I read somewhere that you don't need to use all of the clutch springs. How many should I use and is this causing it to not change gears?
 
Discussion starter · #2 ·
Alright so after reading a lot of posts and still not finding usefull instructions I have determined I need to take some of the HD springs out. But I stil don't know how tight to tighten those 6 bolts.



Any help with how tight? Also what should I set the clutch adjustment on the case at. I remember trying to adjust that before putting the springs in and have no clue where it is at. I feel like it put it as far in as I could make it go so as tight as I could turn the flat slot from the outside.



Any help?
 
#3 ·
I tighten all the clutch spring bolts down till they stop .. Idk the proper spec . :)



You need to re-adjust the clutch tension on the side cover so there is some play in the shift lever .



Start with max loose and the slowly turn it till there is ALITTLE tension on the bolt and then turn it in the opposite direction roughly 1//8 to 1/4 turn .
 
#6 ·
braaap11889 said:
Alright last sentence makes no sense to me.



What do you mean by max?
Click to expand...


Max means ..., loos'est setting --or -- most free play .



The amount of free play that the shift lever has before any type of tension is felt in the shift lever ..



I adjust my shift levers just like I would a clutch lever at all .



Just make sure to leave a tiny bit extra free play in the lever cause as the motor heats up and everything expands , it won't put extra pressure on the clutch as to push it in alittle bit and cause the clutch to slip ..
 
#10 ·
" So you mean loosest the shifter can be or the adjuster on the case ? "



Adjuster on case ..





"and by loose that actually means more of the aduster sticking out of the case correct?"



What ever way makes the most free play in the clutch adjustment .







I believe the screw on my bike is either flush or sticks out alittle futher past the nut when is properly adjusted ..



I have 4 springs in mine .. But mine is a completely stk 110 motor too ..
 
#15 ·
Go to the articles section on Fourstroke Homepage and you can see my stiff clutch springs installation article with pics. If it's all correct like in the pics, just adjust the clutch like in the service manual. The adjuster on the side of the clutch had a lock nut with flat blade screw in the middle. I think it says to loosen the lock nut, back the screw out, then turn the screw in until it stops, then back it out 1/4 turn, then tighten the lock nut. It's something like that.



Oh yeah, and you really should just use 3 stock springs and 3 stiff springs unless you have a really mod motor. I use that set up on my stock motor, on my BBR 143 with VM26, and on my TB 143 with V2 head and VM26 and it works great on every one.
 
#17 ·
Tell us what you replaced or even took apart before you had this problem ..



If you put the 143 kit in at the same time ? Maybe you did something wrong with the crank shaft mounted clutch ??
 
Discussion starter · #18 ·
I put the centrifugal clutch on the crank. Tightened it down as tight as I could get it casue thats what people on here told me to do. I didn't have good rebuild instructions cause I was using an online one for a 134 kit but mostly the same thing.



I put a new topend on and and that clutch nothing more that I can think of right now.
 
#19 ·
braaap11889 said:
I put the centrifugal clutch on the crank.
Click to expand...




Why did you mess with the auto clutch ?? Were you run'n a manual before ?



Did you completely take apart the auto clutch ?



Cause , maybe you might have put the one way clutch in backwards if that's possible ?? idk ?? .. :)



Or ... , Maybe you put that really thick spacer that the bearing fits around , in up side down ?? It has a step machined into it . so ... idk ???
 
Discussion starter · #20 ·
I was running a manual clutch before but not on this motor.



What is the "auto clutch" I got the motor in a box needing a rebuild so I had it rebuilt.



Oneway clutch? I couldn't have put the centrifugal clutch in wrong the threads aren't long enough



Bearing?



The farthest I got into the clutch setup was the springs took that cover off and thats it.
 
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braaap11889
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