Something Wrong with clutch/ cable?

[jigggawatt]

I bought a 2001 kx500. I can get the right amount of freeplay with stock
clutch cable. It has all of the adj. out of the cable though. I tried two motion pro cables and I don't have enough free play. So now I know it's a problem with the bike. I pulled out clutch plates and measured fibers and plates. All of the fibers and plates measured good . I don't know where my freeplay has gone. Has  anyone ever had this problem , if so how did you fix it?

[hughes]

Since you have the clutch torn down check the outer clutch hub for part number 13091-1582 this a push rod holder that goes inside the outer hub. Part number 92022-269 is a washer that goes under the push rod holder. This washer could be missing. The idea here that if the washer is missing then the push rod hold will be to deep inside the outer hub. When your clutch arm is pulled forward by the cable it pushes the push rod in return the push rod pushes out the outer clutch hub causing the clutch action. With that washer missing the clutch arm could be rotated to far forward just to start to make contact with the push rod itself. Before you took apart the bike was the clutch arm pointing straight across the crank cases?? With worn clutch plate or missing parts the clutch arm will be rotated to far forward. Sorry if this sound confusing but I'm not real good explaining these things.

[jigggawatt]

Thanks for the help. I put it back together ,and may have to pull it back apart to check the washers. The arm is rotated to the rear of the bike about the 1 o clock position.

[hughes]

Thanks for the help. I put it back together ,and may have to pull it back apart to check the washers. The arm is rotated to the rear of the bike about the 1 o clock position.

Sitting on the bike and looking down at the top of the clutch arm it should be at a 3 o clock position.

[jigggawatt]

Mine is more like 4 o clock

[hughes]

Mine is more like 4 o clock

Is that with the cable connected? 4 o clock should be right. I'm going off of my bike which is just alittle older than yours     Maybe some else will report their clutch arm location for the newer bikes.

[hughes]

You dont' have a new O.E.M cable? It would be nice to compare the Motion Pro cable to the O.E.M in length.

[jigggawatt]

No I thought it was the motion pro cable. They stepped up and sent me a second cable free. It still wouldn't work. The stock cable has about 3/8 free play with the cable adj. to the shortest housing length. I'm going to pull it apart again and look for the washers.

[hughes]

How much do you need for the second motion pro cable you have?



Can you post a few photo's of your clutch parts and maybe your clutch cable adjustments. May help some others to come up with some ideas.

[jigggawatt]

The price of shipping will get the second cable

[jigggawatt]

Update: I found everything was put together right. So I took a little of the clutch push rod and now pletty of adjustment.