Maintenance & Technical > KX500 Original
Trans problem
John:
Make sure your clutch cable is in good working order and that you have a a bit of play when the clutch is not engaged. If the cable is not OK or properly adjusted, it could cause the clutch to be permanently engaged. This would be noticable under the conditions you described.
The effect is that the clutch does not 'return' properly after it has been engaged, try an additional spring on the clutch lever (on the engine side) if noting else works.
Your choise of engine oil could also be causing problems. Oils with silicone and engine saving low friction stuff could have this effect.
//John
Polar-Bus:
--- Quote from: kx5tsi on September 30, 2006, 01:08:36 PM ---well got it all put back together and now a new problem, this was happeneing right before the bolt fell off letting the gear selector go.
Im assuming my clutch is going bad, I thought it looked good, but I really don;t know what im doin with bikes, im going to go look at new clutches on monday to see how much material is on a new disc compared to mine.
I have a problem where 1st and second gear grabs good until high in the rpm range when it lets loose. 3rd gear really wont grab at all, neigther will 4th or 5th. It just free revs and bucks a little bit, like its slipping but trying to grab. Anyone got any ideas? Thanks,
kyle
--- End quote ---
Make sure you also replace the clutch springs!! Clutch springs on a 20 year old bike frequently become "laxed" and loose much of their "free height".
kx5tsi:
hmm. Well I have a few things to try now thanks to you guys, what is the best oil to run in these bikes? Im running 80w 90w gear oil.
thanks for the help,
kyle
John:
Hi,
Thought I should help out with some KX500 numbers (in mm if the unit is missing). The service limits are in paranthesis;
Friction plate thickness 2.92-3.08 (2.8)
Clutch spring free lenght 32.6 (31.1)
Friction plate / clutch housing clearence [space between the teeths and the housing] 0.35-0.60 (0.9)
Chutch hub nut torque 98Nm (10kg-m, 72ft-lb)
Clutch spring bolts 9.3Nm (0.95kg-m, 82in-lb)
Also check the clutch housing for cracks. Check the clutch plates for warp and finally check the clutch hub for wear.
//John
kx5tsi:
Thanks,
where would I go about getting parts for this bike? I tried the dealer but it seems kawasaki has discontinued the clutch hub at least, I would assume other parts are discontinued as well.
kyle
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