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Discussion Starter #1
Hello everyone! I have an 05 kfx 400 that I recently put a new timing chain in. When I did that I decided to put a new clutch in it since the original was still in there. Now for whatever reason I cant get the clutch to disengage but I can find every gear just as easy as before. Idk what to do I've tried adjusting the cable both on top of the motor and at the handlebar and it doesnt seem to make a difference. Hopefully someone knows what I did wrong!
 

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I hope you soaked the plates in oil overnight before installing them. That could cause your issue and will burn up a new clutch quickly.

You have to check the clutch basket for wear at the point where the tabs stick out of the “fingers” of the basket. They wear grooves in the fingers over time and keep the clutch from disengaging.

I’m assuming you have the correct number of plates as the one you took out. 05 was the year they added an extra set of plates.

If all of that is good, you may need to jump teeth on the clutch shaft arm so the cable only has a little slack in it, then adjust at the handle.
 

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Discussion Starter #3
Yea I soaked them overnight and put in the same number of plates that I took out. Both the basket and hub looked fine to me no visible signs of wear. When you say jump teeth do you mean to not turn the shaft all the way counterclockwise till it stops spinning? Or just put the end of the clutch cable on a few teeth off?
 

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Meaning mark the arm’s position on the splined clutch shaft coming out of the top of the side cover, loosen the bolt that clamps the arm onto the splined shaft, and move it over one spline to pull the cable tighter. This gives you more throw, spreading the basket more for disengagement.

Make sure you mark it first so you know where it was in case you jump splines in the wrong direction.
 
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