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05 Klx110 Won't Start After Hydro Clutch Install

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bhd1223

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Discussion starter · #1 ·
Hello all,



I'm looking for some help here. I just finished installing an aftermarket rear shock, kx65 front end, CHP hydro clutch kit, and the takegawa primary drive gear. Now I can't get the bike to start. I'm at a loss. I just keep kicking and nothing. It doesn't even sound like it wants to start. I am trying in neutral and haven't done the bump start mod. It at least sounds like it wants to start when I try to bumpstart it though.



One thing I noticed is if I try to kick while holding in the clutch there is nothing. The kickstarter just freewheels. Is that normal? I've never dealt with a kickstart before so it's all new to me.



Thanks for any help you can provide.
 
#2 ·
That's strange. Are you sure you installed the primary drive gear correctly? I had a hydro clutch on my last 110 and my current 110 (full mod motors) and the kickstarter never freely spun when I had the clutch pulled in.
 
Discussion starter · #3 ·
Nope. I'm not sure I installed any of it correctly to be honest. The instructions were just IPBs. What I did was pull the case cover off, loosen the nut on the primary and secondary clutch, pull off both, put the secondary back on with the drive gear which was a pain to get all lined up together, and then put the nuts back on each torqued down. Then I put the bearing holder and bearing back above the nut on the clutch pack, the spacer on the splines of the release lever shaft, got the hydro clutch all hooked up and bled, put it all back together, and am now here. Oh, I did install the heavy duty clutch spring kit with all 6 springs as well during this.



Removed items are the release lever, release cam, release ball assembly, entire primary clutch assembly, and the clutch adjustment bolt/screw from case cover for hydro clutch install.



I followed the service manual for removal, however for reassembly most of it didn't apply. I just stuck the primary drive gear on there in place of the primary clutch assemlby. Was this supposed to be lined up a certain way like the primary clutch is supposed to be?
 
Discussion starter · #7 ·
I pulled it and it looked terrible. I cleaned it up a little but it still looks bad. Wouldn't start with it cleaned but plan on replacing it tomorrow anyways. It was only sparking 1/3 to 1/2 of the time. Sometimes I would get 2 kicks in a row with spark but more often then not there would only be spark on 1 of every 3 or 4 kicks. I assume this is a problem.
 
Discussion starter · #8 ·
Well I got a new plug today. Spark looks good as long as there is a strong kick. Same issue though, doesn't even sound like it wants to start. Would the best thing to do now be the bump start mod and see if I get anything from that?
 
Discussion starter · #10 ·
TONY@STATE8 said:
sounds like the clutch is slipping and not spinning the crank over.
Click to expand...


True when I pull the clutch lever in. When I don't it does turn the crank over but doesn't feel like it used to. I guess slip would be the best way to describe what I'm feeling different. It sure feels softer and sometimes feels like a slight slip. What would cause this? Could it be from too much fluid in the clutch system?
 
#11 ·
never used a hydro kit myself, but did some machine work for a group of guys who bought the brand x minis kits. the piston inside the clutch cover was to long and putting pressure on the clutch when the cover was installed, causing the clutch to slip. they had the same issue as you. clutch would slip when they try to kick start, and not spin the crank over.



i wouldnt think that you should have that issue with a chp product, as his stuff is aways pretty nice quality. but i would call and ask if your sure that you have everything installed right.
 
Discussion starter · #13 ·
Thanks for all the info so far. Sometime this weekend I'm going to do the bumpstart mod by grounding that light green wire and see if I can get it started that way. I'll report back what happens.
 
Discussion starter · #16 ·
Jordan - I tightened the primary drive gear to the same torque specified for both the primary and secondary clutches using a torque wrench. Just to make it clear, the crank does turn over when I kick it unless I'm holding in the clutch lever.



AK - I did have to remove the clutch adjustment bolt on the case cover to install the hydro clutch. I'm not sure if this is what you're referring to though.



By chance does the secondary clutch and the primary drive gear have to be aligned in a certain manner? I figured since both are on shafts with splines and they are gears as long as I got then on together it would be fine. The only thing I notice in the service manual is a mention of needing to align the primary clutch assembly which I'm not using as I have the gear.



Again, I'll get to the bump start mod this weekend and see how that goes. I'm really at a loss here. I'm feeling that maybe I should check the valve clearance but I'm not sure why since it was running before I pulled it apart. The gas in it is somewhat old, maybe a month or two half filled. Maybe I should fill it with fresh stuff if the bump start fails.



One thing I noticed when I had it apart was that the kick shaft almost seemed bent down a little bit. It was as if it wasn't straight. Back at the gears it looked straight but in the part covered by the case cover not so much. Again, it ran before I pulled it apart so I don't see how this could be a problem.



Kicking doesn't seem to turn it over as much as I remember but I know it turns over many times bumping it. I'm hoping the bump mod cures my problem and if so I'll just always bump it. Hopefully the thing doesn't blow apart when it starts though. Worst case I guess that just means I go big bore before I was planning on it.
 
Discussion starter · #17 ·
Don't I feel like the big idiot.



I'll let you guys take one guess on what it was. One word hint: fuel.



Yes, I had the petcock turned off.



I guess the best part of this was it forced me to do the bumpstart mod which I would have neglected otherwise and it has a fresh plug. Bumpstarts like a champ too.



Thanks again for all the help. I just feel like a moron now.
 
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bhd1223
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