Maintenance & Technical > KX500 Original

Something Wrong with clutch/ cable?

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jigggawatt:
I bought a 2001 kx500. I can get the right amount of freeplay with stock
clutch cable. It has all of the adj. out of the cable though. I tried two motion pro cables and I don't have enough free play. So now I know it's a problem with the bike. I pulled out clutch plates and measured fibers and plates. All of the fibers and plates measured good . I don't know where my freeplay has gone. Has  anyone ever had this problem , if so how did you fix it?

hughes:
Since you have the clutch torn down check the outer clutch hub for part number 13091-1582 this a push rod holder that goes inside the outer hub. Part number 92022-269 is a washer that goes under the push rod holder. This washer could be missing. The idea here that if the washer is missing then the push rod hold will be to deep inside the outer hub. When your clutch arm is pulled forward by the cable it pushes the push rod in return the push rod pushes out the outer clutch hub causing the clutch action. With that washer missing the clutch arm could be rotated to far forward just to start to make contact with the push rod itself. Before you took apart the bike was the clutch arm pointing straight across the crank cases?? With worn clutch plate or missing parts the clutch arm will be rotated to far forward. Sorry if this sound confusing but I'm not real good explaining these things.

jigggawatt:
Thanks for the help. I put it back together ,and may have to pull it back apart to check the washers. The arm is rotated to the rear of the bike about the 1 o clock position.

hughes:

--- Quote from: jigggawatt on March 02, 2007, 02:00:03 AM ---Thanks for the help. I put it back together ,and may have to pull it back apart to check the washers. The arm is rotated to the rear of the bike about the 1 o clock position.

--- End quote ---


Sitting on the bike and looking down at the top of the clutch arm it should be at a 3 o clock position.

jigggawatt:
Mine is more like 4 o clock

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