KX Riders

Maintenance & Technical => KX500 Original => Topic started by: Fookeneh on April 06, 2004, 03:32:02 PM

Title: clutch lever bearing
Post by: Fookeneh on April 06, 2004, 03:32:02 PM

The shaft on the lever is worn as well as the bearing.The shaft is a no-brainer but replacing the bearing looks tricky without dropping the needles into the crankcase. Any suggestions?

Title: clutch lever bearing
Post by: mikesmith on April 06, 2004, 08:01:56 PM

They should stay in the cage,but thick grease works for holding.

Title: clutch lever bearing
Post by: kawdude on April 07, 2004, 05:31:50 AM

Replacing the bearing(s) is tough...especially the lower bearing.  Keep the clutch rod that the lever operates in place and the should protect from needles falling in the crankcase and use a magnet to remove any that do fall out.  I did this replacement last year and it's doable but not fun,

Title: clutch lever bearing
Post by: Fookeneh on April 07, 2004, 07:41:56 AM

I didn't even see a lower bearing.Do you modify a slot screw driver to pull the bearings out the top of the hole?

Title: clutch lever bearing
Post by: kawdude on April 07, 2004, 02:03:08 PM

You can try that first and see if they come out.  Mine were too tight.  I had to drill a hole at the bottom of that tube big enough to get a small but long punch in there and beat the bottom bearing out the top of the casing.  Putting them in isn't bad though.  I filled the hole with JBWeld.

Title: clutch lever bearing
Post by: Fookeneh on April 07, 2004, 05:57:24 PM

I don't have alot of experience with J-B but it sound s  as though it worked for you. Depending on how thick that casting is a guy might be able to thread a plug in there with lok -tite . I like your idea, it sounds simple. 8)

Title: clutch lever bearing
Post by: kawdude on April 08, 2004, 05:38:32 AM

I thought about the plug also but thought that the bottom of the shaft may contact it.  I don't remember how thick the casting is but it not very thick 3-4mm at the most.

My fix is rough but simple.  Someone may make a puller but I could not find one that was small enough or long enough.  Seems like I found one that was small enough but was no where near long enough to reach the bottom bearing.

Title: clutch lever bearing
Post by: kawdude on April 08, 2004, 05:40:24 AM

Could try freezing the engine.  That may contract the bearings enough to pull out.

Title: clutch lever bearing
Post by: Fookeneh on April 08, 2004, 07:55:48 PM

Thanks for the info. I am going to extend the lever 8mm to ease clutch action and at the same time I will try brazing and filing the worn part of the shaft. I will pull the motor when the season is done and go through it all properly. Hopefull I can get it tight enough to keep the seal doing it' s  job.

Title: clutch lever bearing
Post by: kawdude on April 09, 2004, 07:35:15 AM

I think 8mm is too much.  I think I've heard 4-5mm max.  Do a search on this site.  There was a discussion about it.