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Author Topic: KX500 HEAVY CLUTCH PULL, WHAT CAN BE DONE  (Read 161 times)
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sandblaster
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« on: October 10, 2018, 07:15:15 PM »

By now I'd say most of you guys know what is being done to lesson clutch pull.
1. Straighten the cable a bit where the metal shield is at. And make sure the cable is new.
2. Cool aftermarket clutch perches.
3. Extended clutch puller arms.
4. Hydraulic clutch.
5. Basket and hub in good condition.
The other day Jason Tanner finally confided in me some ideas he has.... I think each one has merit but we need to be able to test each one out. Out of respect for Jason's idea's I can post pics of what he came up with. But I will be posting results from each experiment to see what can be done.

Any idea's you may have would be welcome. We are looking for simple effective idea's that can be done by most guys with limited tools. (Like me).

The first thing we did was put together a mock up testing stand.. Nothing better the genuine Kawi parts smiley

Once we get this together we will be doing some really cool testing so stay tuned..


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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.
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« Reply #1 on: October 10, 2018, 07:30:46 PM »

Travis Saturley:  I move the clutch (and brake) perch in towards the middle of the bars. This causes me to only use the end of the lever, increasing my leverage. I have long fingers, so that may not work for everyone.
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.
dave916
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« Reply #2 on: October 11, 2018, 02:49:30 AM »

Genuine cable or one with swivel ends  {well lubed not ky grin}
Good needle rollers in cases

I Can pull my clutch with on finger all day long
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Foxx4Beaver
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« Reply #3 on: October 11, 2018, 07:51:06 AM »

Genuine cable or one with swivel ends  {well lubed not ky grin}
Good needle rollers in cases

I Can pull my clutch with on finger all day long

I agree...I'm runnin a completely stock clutch.
Keep the cable up to par and well lubed...pulls almost as easy as my 250.
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« Reply #4 on: October 11, 2018, 03:33:39 PM »

To test all our idea's I need a very accurate test fixture..
So, I grabbed my best spare engine cases and set about gettin it done  shocked



Hello MR. Sawsall





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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.
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« Reply #5 on: October 11, 2018, 03:35:29 PM »







Well... let's get rid of that pesky casing that covers the bottom bearing.
This will help later on during testing...   grin

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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.
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« Reply #6 on: October 11, 2018, 03:35:58 PM »

Something like this....



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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.
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