KX Riders

Maintenance & Technical => KX500 Original => Topic started by: sigurd on March 18, 2007, 04:13:35 PM

Title: Installing a new clutch on my KX500
Post by: sigurd on March 18, 2007, 04:13:35 PM

I am the proud original owner of my 95 KX500. I have had zero issues with this bike since I bought it. I had a new piston and rings put in it about three years ago just because. Now I'm going to do the clutch. I bought all new friction and metal plates. Also, new springs, a clutch cover gasket, a quart of oil and some new coolant. Do any of you have any tips for me when installing a new clutch?

I'm new here and thought some of you would know whats up.

Thanks much from San Diego Calif!

James  :-P

Title: Re: Installing a new clutch on my KX500
Post by: Danger4u2 on March 18, 2007, 04:38:33 PM

I had starter issues but the clutch had to come off to fix the problem.  Here's a link to my pictures.  http://www.kxriders.com/coppermine/thumbnails.php?album=80  Get a clutch holding tool, it made the job easy for me.  Check the picture with the file in it.  The weld on the frame would not let the cover come off of the engine.  That's an easy job.  Let us know how it goes.

Title: Re: Installing a new clutch on my KX500
Post by: sigurd on March 18, 2007, 04:48:32 PM

Hmmmmm, I dont need to take off the basket, just the plates. Not sure why I would need the clutch tool. Nice pics. My 95 did not have the weld in the way. Thanks for the reply.

James

Title: Re: Installing a new clutch on my KX500
Post by: doordie on March 18, 2007, 08:18:23 PM

Put the frictionplates first in your motoroil for a 24h,so you don?t "burn" them first ride. :wink:

Title: Re: Installing a new clutch on my KX500
Post by: Danger4u2 on March 19, 2007, 02:54:32 AM

Quote from: sigurd on March 18, 2007, 04:48:32 PM

Hmmmmm, I dont need to take off the basket, just the plates. Not sure why I would need the clutch tool.

Your right you won't need to remove the basket.

Title: Re: Installing a new clutch on my KX500
Post by: scotscooby on March 19, 2007, 08:17:48 AM

Just a small pointer, be careful not to over tighten the bolts they can strip the alloy really easy in the clutch housing. Use a torque sequence when you tighten them. I have looked for a torque setting for these bolts but cannot find one so it will be a matter of feel unless anyone else knows the setting.

Title: Re: Installing a new clutch on my KX500
Post by: MadKaw on March 19, 2007, 12:26:08 PM

according to the manual, those bolts are 82 inch-pounds

Title: Re: Installing a new clutch on my KX500
Post by: Polar-Bus on March 21, 2007, 04:12:06 AM

All excellent comments, and lastly, do NOT be tempted to add Barnett race clutch springs. Barnett springs are SOOOOOO stiff !!

Title: Re: Installing a new clutch on my KX500
Post by: MadKaw on March 21, 2007, 04:21:59 AM

arm pump anyone?

Title: Re: Installing a new clutch on my KX500
Post by: jigggawatt on March 21, 2007, 11:52:55 AM

I run the Barnett springs on every other one. Three stock and three Barnett.

Title: Re: Installing a new clutch on my KX500
Post by: KXcam22 on March 21, 2007, 05:20:20 PM

I like to use anti-seize on the 6mm case bolt threads and 6lbs torque. Cam.