Maintenance & Technical > KX500 Original
Clutch Issues *PLEASE HELP*
tha.steev.oh:
I have a race in less than a week and I'm summoning all the KX500 gurus on the site - hoping someone could lend me some pointers.
Here's the situation:
- I'm feeling a slipping (not direct engagement) when I'm shifting gears. The revs hang up for a second before it comes down and starts driving. I do my own wrenching but I've never had to change a clutch before and I'm not looking forward to pulling the entire side of my bike open just to change plates, springs, etc. What a poorly conceived design! :?
- I bought this bike last fall and it was in prestine shape with original sprockets, tires, and not a mark on the frame so although I don't know the history, I'm assuming it was babied (original clutch I'm sure). It's a 2001 K5 and is set up for primarily supermoto. I have a 14oz Steahly flywheel weight so there's actually little clutch abuse since I never have to slip the clutch to grab revs. The clutch pull has always been quite stiff but I don't have another K5 to compare it to so assumed it was normal. I have 15/40 gearing. I run ATF Type-F and change it after every weekend of riding.
- What do I do? I need to order parts asap so should I just bite the bullet and buy the whole clutch kit and gasket or do you think something else could be the issue?
Any help would be soooo appreciated :-)
steev-oh
kaw rider:
another transmission problem with atf oil in it. you will have to pull the cover to find out. maybe a notched clutch basket , broken clutch springs , worn plates, burnt up plates
Friar-Tuck:
Hey Steve,
If you can afford to buy the clutch kit and have it on stand by it surely wouldn't hurt. The parts are consumable so they will have to be changed at some point. However Once the clutch starts slipping it usually goes down hill quick.
I think you'll find once you get the bike opened up it's not really that big of a deal.
Is it really worth getting to the track and hoping the bike will make one more moto?
My vote is "an ounce of prevention"... I wouldn't meet the guys out at the trail head without knowing the bike was 100%.
Look through your service manual and get what you need.
The only thing you really have to watch is not trying to hold the basket with anything other than the vice grip looking jobbers, and re-installing the clutch springs and retaining bolts. Be careful re-installing those suckers... check the torque specs and use them.. don't attempt to "snug up" the bolts they will break and you will be mad.
I aplologize for not adding piccy's and all I got to get to work... be back in a few days...Look for a vid for some reference.
Tuck\o/
madmick:
steev.oh..it might sound silly but have you got a 2/3mm gap between your clutch perch and clutch lever,sounds like it might be engaging and no slack in your cable to allow it to fully disengage when released will cause similar probs..?..good luck..if not and you take your plates out make sure you keep them in the same order they came out to go back in..
Danger4u2:
--- Quote from: madmick on August 23, 2010, 12:33:38 AM ---steev.oh..it might sound silly but have you got a 2/3mm gap between your clutch perch and clutch lever,sounds like it might be engaging and no slack in your cable to allow it to fully disengage when released will cause similar probs..?..good luck..if not and you take your plates out make sure you keep them in the same order they came out to go back in..
--- End quote ---
I think when you say "no slack in your cable to allow it to fully disengage when released will cause similar probs..?..". Your talking about the cable disengaging. It just sounded a little odd because when you release the clutch handle the clutch will engage.
Just wanted to make sure everyone knows what your saying. You are correct if the cable has no play the clutch will not fully engage.There should be enough slack to slip a nickel between the perch and lever.
Here's a picture of the clutch tool. When you go back together make sure you get the ratchet spring in the little slot. I missed that and had to pull it all apart to correct it. You shouldn't have to mess with that, just thought I would point that out. You can see the little dent the spring put in the plastic as I tried to bolt up the side case.
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