Maintenance & Technical > KX500 Original

Clutch Change

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stock500:
I have never had to replace a clutch on any of my older bikes, but I think my 2004 500 is in need of a clutch.  The clutch is not slipping when I accelerate, but the shifting seems to be a little more harsh, and I just changed the oil.  When I pull the clutch in and I am just coasting to a stop, as I downshift the rpms jump a little bit each time.  Also when I am stopped and I put the bike in gear It almost kills on me because of the drag on the motor.  The clutch pull feels like there is plenty of room in the range for the clutch to engage fully.  What do you guys think. 

P.S.  If I replace the clutch should I get heavy duty springs?  My bike is bone stock.

kxraptor:
I recently replaced my clutch [93' 500],and opted for the heavy duty springs.All works well but the heavy springs added about 25% more effort to the clutch pull.The replacement clutch I got was an EBC from Rocky Mountain[excellent service].

Texas Champ.:
Stock: You don't need a clutch you just need to adjust the one you have ....when you pull the cable it isn't moving far enough to disengage the clutch......screw the adjuster out at the clutch perch so it has about 3-4.. between the lever and perch at the widest point of the gap....if there isn't enough adjustment room there  you'll have back the adjuster in, then go down to the cable adjuster on the motor and get some more cable tension there (not too much) but to where you can finish the adjustment at the clutch lever......that way it gives you a place to adjust it without needing tools

Raptor : By an "EZ-PULL" for your clutch...I got one and love it.........km

hughes:
It's been awhile since I have been around the 500 but I don't remember any adjustment to made for the clutch cable down at the engine. Sounds like you clutch plates are sticking together, from a dead stop that would cause the bike to stall or even surge forward while holding in the clutch and shifting the engine into gear. Over heated clutch plates like to stick together.

Hillclimb#42:
There is the adjustment at the lever and another at the number plate.(Front Plate) You should have some play in it. It should not be tight to the perch. If you are tight to the perch with no adjustment then you need to replace the cable or clutch disks. I've found that mine needs to be a little tighter after warming up and that I always have a little drag when in gear. Thats why it is easier to start in neutral. IMO, you are not needing a new clutch, unless there is a bunch of hours on it. I don't quite get the downshifting issue, but it could be the k5-surge that is common to them all. Be sure not to overtighten clutch pivot bolt, also. It is backed up with a nut so you can have an easier clutch-pull.

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