I'm back on the road again! It took a while for my parts to come in at the local bike shop. Had her all back together in a couple of hours.

I think that the basket nut was overtorqued, as it seemed to take A LOT more force to break it free than when I torqued it back on. To break it free, I ended up putting the bike in high gear, wedged a block of wood in between the chain and rear sprocket, straddled the bike, stepped on the brake and put a four foot section of conduit over the handle of the 1/2" drive breaker bar.

The clutch was toast -- I should have realized that it was getting burnt up, but I couldn't see that the rear wheel wasn't turning as it was completely buried in the mud hole.

I replaced the whole clutch, steel plates, friction plates and springs with Barnett components. The clutch seems to be a bit grabbier.

I'm going to change the oil a couple of times more over the week or two to make sure I get all of the grit out from the old friction plates.

Here's a correction to the Barnett part numbers -- these are from the Off Road Unlimited catalog that the bike shop used:

2012-112 FITS MODEL: KLX300/R 97-05, QUANTITY PLATES REQUIRED: 7 - INDIVIDUAL KEVLAR FRICTION PLATES
KP-8-16 FITS MODEL: KLX300/R 97-05, QUANTITY PLATES REQUIRED: 6 - INDIVIDUAL STEEL DRIVE PLATES
2012-323 FITS MODEL: KLX300/R 97-05 - CLUTCH SPRING KITS

It's been raining a lot here in Northern Colorado and I'll bet that Old Flowers Road is even muddier now. I checked the Forest Service website and saw that they re-closed it. Maybe ina week or so, I'llget back up there. ...wonder it that truck ever got out of there?

 

Glad to hear your going again be a good idea to add those part numbers to the part number sticky at the top of the forum
Cheers