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Enduro Engine - 2 stroke Cylinder, Piston, Tranny, Bearings, Clutch, Pipes & Silencers, etc.

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Old 05-23-2008, 12:30 PM
stay_upright's Avatar
stay_upright stay_upright is offline
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Join Date: Jan 2008
Location: Coventry UK
Posts: 460
Default New DP clutch plates won't fit - suggestions?

Stuff like this always happens to me - new DP clutch and the steels don't fit.

The lugs on the inside seem fractionally too wide so it *just* won't go onto the basket. I managed to push one steel on but it was tight and I can't see the clutch working with that much friction to move the steels....

So I either file each lug a little = 32 lugs/plate x 7 plates = lots of filing.

Of get GG OEM plates but that's time and potentially a lot of money (upto £10 each? = £70 not £18) and of course I'm racing on Sunday so it would be nice if I could start the bike in gear and for it not to repeatedly stall in the woods (stalled 20-30 times last race)

I checked the clutch codes and the kit is correct for a 96-2006 EC model...

I'm thinking i'll get the file out after a cuppa tea...

Anyone know if I will damage (warp) the new frictions if I use them with the old steels?
'05 Gas Gas 300
'97 Aprilia Pegaso 650
'99 KTM 200
'95 ish XR630 (died many times in Oz)
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