Klx 250 & ebc clutch woes
 

Where to begin? From the beginning I guess.

Bike is a 2018 KLX250s.

Burnt the stock clutch out about 2000km due to not rerouting clutch cable after fitting higher bars.

Fitted a longer cable and EBC clutch and burned that at about 10k after what I figured was hard use enduro. Oh well. Figured it was time to beef up the 250 at this point.

Fitted another EBC clutch with 330cc kit, and now at 16k kms, the last few times I've been out it's been slipping when leaving the house for the first 10 minutes. Once the engine warms up its been good to go.

I've been doing 300km ride days recently so replaced it today with another EBC DRC 212.

So I took it to my mechanic. He's very thorough and only recently fitted the same EBC without issue.

Upon removing the clutch shaft nut, he noted it was over torqued.

So he installs the new clutch, fits a new cable, fresh engine oil. Great. Looks good. Time to test the bike and the engine just drags in gear.

After pulling it out and reinstalling 4 times, checking the spec of parts against the klx250 repair manual and it's still dragging. Can't work it out. We even tried to put some steel plates from the used clutch in because when all the new clutch plates were assembled it was a tiny bit under spec.

We were close to just putting the old one back in so I could ride home, mission failed, when we decided to remove the judder spring.

With just spring removed, it sad all reassembled (5th attempt) and what do you know... IT WORKED!

So my mechanic took it for a test ride and returned to say it was working as it should. I ride home 30 minutes and no issue. Works as a new clutch should.

So it's got be beat. I'm posting this in an attempt to work out why the just spring needed to be removed for it to work. Will it need to be put back in at some time?

Can't say these EBC clutches are serving me well.

Should I definately fit the Barnett springs as I have seen on various threads today while trying to solve the problem.

Any insight appreciated.

Thanks

Edit: I forgot to mention the springs that came with the kit were 1mm longer 🤔

Edit 2: some grooves were noted in 2 of the clutch basket spaces the plates side into. Not deep, but noticible to the eye and running finger across... Perhaps???