Maintenance & Technical > KX500 Original

Clutch Issues *PLEASE HELP*

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tha.steev.oh:
My clutch cable play is to spec - I had hoped this was all that was going on.
I'm gonna buy the clutch kit today since like you said Tuck I will need to replace them sooner or later anyways. Can't afford to pay to go race and bring a limping clutch along. I would hate to bring a knife to a gunfight.

Is that clutch holder necessary to pull the top plate off and change the plates and springs? Or is that for full basket removal? If so is there a way to hold it and not damage anything without that special tool?

You guys are awesome! I appreciate the lightning-fast reponses!

steev.oh

madmick:
steev oh wait until you dismantle the cover before you fork out your hard earned as it could be some bolts have loosened up and just need tightening or maybe even marks on your basket causing your plates to stick in the grooves and not move freely,the tool shown clutch holding tool is about 40-50 bucks down here and you will be needing that to hold your basket while you tension and re-tension the nut when putting the basket back on,i made my own i got 2 pieces of steel that fit fairly snug in the grooves and then welded them together with 1 longer piece that acts as your handle so it will look like the letter F,or a material strap spanner will hold it and not damage the surface as well(bush method)from the bush mechanic..

Danger4u2:
Here's the kind of strap madmick's talking about.  You can find them for 5 bucks.
Lisle LIS63500  This one opens to 6 inches.

Friar-Tuck:
 Or if you have acsess to a welder I have seen guys take three or so plates weld them together and add a handle.
   You won't have to remove the basket if you just want to replace the fibers and or plates.   If the Basket is grooved I guess you could file the grooves out while in the bike,-- however those filings will inevitably get everywhere..
  There are a few "Other" or "Bush" methods one could use.. I mean sometimes you have to do, what you have to do..
 Please understand I'm not attempting to sound  self righteous...I have way too many embarrassing fixes and too much breakage, I'm not very proud of that......
  I just hesitate telling someone with maybe not as much time spinning wrenches and have the inevitable happen, that wouldn't look good for the site or the poor bloke with the broken parts..

I know that fancy pair of vice grips isn't cheap, however you will be able to use them on plenty of other bikes..(if that helps justify the cost)
  I broke the basket on my XR600 the first time tearing down the engine,  that cost me about $100.00,   and then when I finally got the new basket, 
I broke two bolts on the clutch spring /pressure plate.  It wasn't too bad getting the bolts out but those bolts were expensive...( I didn't think I should replace them with bits from the auto supply)

  Another thing to remember is to fully wet the plates before installing  them in the bike.
 Don't try to get the side cover off without removing the brake pedal, it's not worth spending the time wrestling it around only to realize you have to remove it anyway.
 Pay attention to the order of the washers and spacers etc. If you have a digi cam take some photo's and or good notes. 
 When installing the bolts in the pressure plate go around them evenly until they bottom.  And use a torque wrench! :-D
  You Can Do It!!
  Tuck\o/ 

 Simple clutch pack R&R: http://www.youtube.com/watch?v=br63PLcq3sU

tha.steev.oh:
Update:
Got the EBC DRC series clutch kit (including plates and springs) today. Just waiting on the clutch cover gasket - should be here tomorrow. Gonna start tearing it open tonight so I: A) have time to do it carefully & B) have time to grab other parts if they are needed before the weekend.

- Someone told me I should change the water pump seal while I'm in there since it might get damaged on removal. What do you guys think? Good idea?

Tuck: FYI - I don't read any "self-righteousness" in your response. I asked kxriders because I've been visiting for almost a year and I respect all the experience and best-practices you members can lend me. I'm more than impressed with the help I've been getting.

Keep smokin'!  :-D
steev.oh

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