bron yr aur

You guys are awesome! Thanks so much. I now remember a post that described the MC problem of the hole not lining up and allowing the fluid to return. Now I definitely have the excuse to order my conversoin to the newer system. It's fairly inexpensive if I don't buy the new clutch pack. I'll check the MC this afternoon and and post back here. But that definitely matches what's going on here. I think the biggest thing I'm learning here is how to find parts or help on working on it. I have 2 KX 2 strokes. There obviously is a plethora of Japanese manuals and forums. And I even have a Triumph Bonneville, and still so easy to find help and parts. But these GG's are nearly impossible to find help with, other than this forum. Thanks again, all!

Thanks for the quick reply. TBH these are very tiny heads, barely bigger than the originals. In fact, the head looks to be very close in size to the ones you're speaking of. But I will check. And I can make a new gasket tomorrow. Still, I'm wondering why I can feel the fingers engaging as I press the cover against the case. The basket never moved. The only thing I can think of is that the clutch pump piston in the cover that holds the bearing, could it not be retracting far enough? I'm afraid to pull on it, since I don't know if fluid will come gushing out or what? The parts manual shows an O-ring in there, so that has me a little skeptical. I can definitely feel it hit something when I press it back in. I will say it's not seating up against the cover though. I'm thinking I need to pull it tomorrow and explore the cover more in depth.

Hello all. My first post here, but I've been reading up a LOT, for weeks in fact, on clutch discussions for my bike. But I'm baffled on two things: 1) I cannot, for the life of me, manage to remove my clutch assembly, even after removing the center bolt. Is it possible that on my particular model, there is another retaining part that is preventing its removal? I've seen a few videos, including Jim Snell's, and they just casually remove the assembly. On one video, he lightly bumped/pried with small pry bars to dislodge it. But it just doesn't work for me. In all honesty, that isn't my biggest problem, since the assembly doesn't HAVE to come out. 2) Reassembly problem. This all started with a very stiff clutch. The research I did yielded a huge amount of owners whose clutch fibers had swelled. This turned out to be my problem (10.2 mm thickness for the pack). Having just bought the bike, I don't really have the money at the moment for a new clutch pack and the mineral oil conversion. I decided to just lightly sand each side of the 3 discs to bring them into spec. (What the hey? If I ruined them, at the worst I'd buy new) It worked great. Upon install, I measured finger height at around 17 mm. Everything looks good, right? Well, when trying to press on the clutch cover, I realized that I'm actually having to engage the clutch to get it to seat against the case. The stinking cover is bouncing back approximately 5-8 mm. I can get it to seat, but of course with much effort. Any ideas? I can pull the clutch lever and watch it move out inside the cover. Then, I can press it with my thumb back to its origin, and feel the thing bottom out. As far as my assembly, I next have the bearing, then the flanged washer that rests against the fingers installed. Also, how tight should the 10 bolts be? Finding torque specs on these things has proven to be impossible for me. Basically, since the original bolts (I've since replaced them with tiny hex heads) had a joke of a head on them, I'm assuming there is very little torque needed. I basically snug them slightly once I feel them seat the ring against the post. Sorry for the long winded post. Any help would be GREATLY appreciated! I'm dying to get back on this thing. I've had it less than a month, but the clutch has been killing my left arm. It was 2 fingers for 20 minutes, then a 3 finger clutch. Not good for trials I'm sure.