Maintenance & Technical > KX500 Original

lengthening the clutch arm

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mikesmith:
Forget the 3 position lever(junk)go with the Fly,PC,ASV or works connection on the fly perch and lever as they give better leverage and quick adjust.Lengthen you clutch arm by welding in a 6-8mm extension and you can polish the shaft,reroute the cable (I cant describe how,but I did mine in a more direct way),use a motion pro cable,invest in a cable luber and use it.These are things Ive done for a better pull than most 250's Ive ridden.And Welcome to the best Kawasaki web site!

grtsctt:
Thanks Mike, you are great and fast, and it is the best KX website!
Ty Davis said 5MM, which is small.
Cam said(see post) 10 too much, so he ended up with 5MM.
So, 6-8MM seems long?
I wonder if I could have someone fab me one 8MM long with a second hole at 5MM so I could decide/change to whatever works best?
Question for Cam:what happens when you tried 10MM?(can 10 work with a diff cable etc.)?
I believe you Mike, it's just that 8 is sooo close to 10 when we talk in mm.
I wil prob play it safe with 5, but am tempted to go say 7 or 8 cause I have small hands ans I don't ant beasty clutch to eat my clutch hand.
Sidenote to everyone: I am told Magura in UK makes a Hydraulic clutch like on the stock KTM for around $250, but I was told the feel is weird?
Thanks and keep me posted as I want it right the first time and like butter, and I will take all lof Mikes advice:polishing etc.
Thanks, Me

KXcam22:
GRTSCTT,
   I did 5mm with no problem and combined it with Mikes rerouting of the clutch cable.  The two together made a noticable difference.  My next step would be to put on an aftermarket slippery clutch cable.  One thing to remember is that clutch pull is all about leverage.  More leverage = easier clutch.  Extra leverage can be added at the bar (aftermarket perch) or at the clutch actuation arm (make lever longer).  However, since the amount your clutch lever can travel is fixed (ie. pulled in to the bar is max), more leverage (5mm or 10mm clutch-arm extention) means that the clutch shaft rotates a bit less, so the clutch in not dis-engaged as much.  This is generally not an issue but if the clutch-arm is extended a large amount the clutch could possibly not dis-engage fully and drag.  I have read about those who have done 10mm but not tried it.  As a suggestion, since my 5mm is great you could probably go  8-10 mm with no troubles.  If you have small hands, you could space the lever closer to the bars (a 1/4" lockwasher over the cable beween the lever & housing works great) but then might want to settle for the 5mm so you don't run out of dis-engagement travel.  I am not a fan of dirtbike hydraulic clutches.  I ride with a gaggle of orange bikes and they can't modulate the clutch on nasty technical hills like I can and they all stall lots in the really tough spots (I laugh at them orange guys). Hope this helps. Cam.

mikesmith:
I found a guy whos KTM525 went over a cliff out in the middle of nowhere,and after we dragged it out of there his clutch wasnt working.Im sure it got air in the line from hanging upside down,I wouldnt spend my $$ on one.Thanks for the compliments grtsctt!!

grtsctt:
Cam, what happened when you did 10 MM?
Why was it too much/too long?

Thanks
Scotty/grtsctt

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