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Author Topic: 98 KX 500 Hard clutch pull  (Read 10410 times)

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Offline paiankur

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98 KX 500 Hard clutch pull
« on: September 14, 2014, 01:04:08 PM »
The clutch pull on my 98 KX 500 is extremely hard. All my bikes (250's, this is my first 500) have been cable clutch so I know this is a really really hard pull. After a couple of hours of riding, it is impossible for me to use two fingers to pull in the lever and I stall the bike a bit too often. I know it is not the cable because I recently changed the cable. I have lubed the pivot bolt up really well too. What might help make the clutch pull better (and it would really have to be like a 5X improvement, did I mention it is way too hard? :D). I dont feel like splurging $250 for a Magura Hydraulic and I have heard bad experiences with it too! Any other suggestions? Anyone try the MSR pro raptor or any other EZ pull clutch?

Thanks!
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Offline reklessj

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Re: 98 KX 500 Hard clutch pull
« Reply #1 on: September 14, 2014, 02:11:55 PM »
If you haven't replaced the cable try that. Mine was pretty hard too (but both nothing i couldn't pull in with to fingers) no matter how much I lubed it. Finally it snapped bought a new and its butter. Get a new cable and if that dont help, bulk up dude.
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My rides: 1994 KX500, 1988 T4, 1998, ZXI 1100 JETSKI, 2003 MOUNTAIN CAT 900
WIFES (Baby Fiver) rides: 2004 KTM 105SX,1992 LT250R, 1995 ZXI 900 JETSKI,  2011 RMK 600
SONS ride: 1995 YZ125,2002 RM 250
other rides: 2007 RMZ450 RC Ediition, 2003 RMK700

Offline paiankur

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Re: 98 KX 500 Hard clutch pull
« Reply #2 on: September 14, 2014, 02:17:00 PM »
Quote from: reklessj on September 14, 2014, 02:11:55 PM
If you haven't replaced the cable try that. Mine was pretty hard too (but both nothing i couldn't pull in with to fingers) no matter how much I lubed it. Finally it snapped bought a new and its butter. Get a new cable and if that dont help, bulk up dude.

I have already tried that, new cable and new lever with a lubed pivot bolt and all that good stuff! Helped a little bit but not much. I am 200 lbs (and have stripped several bolts :D) so I have plenty bulk  :lol:
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Offline cmotodad

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Re: 98 KX 500 Hard clutch pull
« Reply #3 on: September 14, 2014, 02:27:57 PM »
Sounds like he needs to look at the arm extension too. I did mine and it is not much more pull than my CR250
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Offline reklessj

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Re: 98 KX 500 Hard clutch pull
« Reply #4 on: September 14, 2014, 04:03:37 PM »
 +1 I was lucky enough to let "the man" sir Motorrad ride my bike back to camp( no particular reason :wink:) and he suggested thae clutch arm and decompress mod. But I'm manning up for now maybe in 10 years or so!!  :lol:
« Last Edit: September 14, 2014, 04:24:50 PM by reklessj »
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My rides: 1994 KX500, 1988 T4, 1998, ZXI 1100 JETSKI, 2003 MOUNTAIN CAT 900
WIFES (Baby Fiver) rides: 2004 KTM 105SX,1992 LT250R, 1995 ZXI 900 JETSKI,  2011 RMK 600
SONS ride: 1995 YZ125,2002 RM 250
other rides: 2007 RMZ450 RC Ediition, 2003 RMK700

Offline sandblaster

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Re: 98 KX 500 Hard clutch pull
« Reply #5 on: September 14, 2014, 04:19:58 PM »
 :-D



Reroute clutch cable from stock position and straighten the metal curve a bit..
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline reklessj

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Re: 98 KX 500 Hard clutch pull
« Reply #6 on: September 14, 2014, 04:27:11 PM »
Quote from: paiankur on September 14, 2014, 01:04:08 PM
The clutch pull on my 98 KX 500 is extremely hard. All my bikes (250's, this is my first 500) have been cable clutch so I know this is a really really hard pull. After a couple of hours of riding, it is impossible for me to use two fingers to pull in the lever and I stall the bike a bit too often. I know it is not the cable because I recently changed the cable. I have lubed the pivot bolt up really well too. What might help make the clutch pull better (and it would really have to be like a 5X improvement, did I mention it is way too hard? :D). I dont feel like splurging $250 for a Magura Hydraulic and I have heard bad experiences with it too! Any other suggestions? Anyone try the MSR pro raptor or any other EZ pull clutch?

Thanks!
Welcome to the forum BTW! You will find a wealth of info from threads on here and the very many guru's on here
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My rides: 1994 KX500, 1988 T4, 1998, ZXI 1100 JETSKI, 2003 MOUNTAIN CAT 900
WIFES (Baby Fiver) rides: 2004 KTM 105SX,1992 LT250R, 1995 ZXI 900 JETSKI,  2011 RMK 600
SONS ride: 1995 YZ125,2002 RM 250
other rides: 2007 RMZ450 RC Ediition, 2003 RMK700

Offline alward25

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Re: 98 KX 500 Hard clutch pull
« Reply #7 on: September 14, 2014, 05:13:03 PM »
MSR pro raptor is great.  Your clutch arm bearings could be bad too.
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Offline Goat

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Re: 98 KX 500 Hard clutch pull
« Reply #8 on: September 15, 2014, 02:04:12 AM »
Quote from: alward25 on September 14, 2014, 05:13:03 PM
Your clutch arm bearings could be bad too.

+1 on bearings binding or wore out.

What brand cable did you buy? I've tried a bunch of aftermarket cables and all of them made it hard to pull the lever. I now only use OEM cables.
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It's hard to keep a drivers license riding a 2 stroke dirt bike on the street.  If you drive within the law they are VERY boring.

Offline paiankur

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Re: 98 KX 500 Hard clutch pull
« Reply #9 on: September 15, 2014, 03:09:41 AM »
Quote from: Goat on September 15, 2014, 02:04:12 AM
Quote from: alward25 on September 14, 2014, 05:13:03 PM
Your clutch arm bearings could be bad too.

+1 on bearings binding or wore out.

What brand cable did you buy? I've tried a bunch of aftermarket cables and all of them made it hard to pull the lever. I now only use OEM cables.
Hmm, I tried the Motion PRO cable.
Quote from: reklessj on September 14, 2014, 04:27:11 PM


Welcome to the forum BTW! You will find a wealth of info from threads on here and the very many guru's on here

Thank you Sir!

Thanks all for replying. OK I am thinking I will get the MSR pro raptor (after all it is supposed to offer a 365% easier pull :)) A large number of you indicated that the clutch arm mod might help so I might buy one of those extensions, the ones that are bolted on, not welded and see if that helps.
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Offline paiankur

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Re: 98 KX 500 Hard clutch pull
« Reply #10 on: September 15, 2014, 04:11:52 AM »
I cannot find any clutch arm extension kits for the KX 500. Most are specifically for CRF 450's or YZ's. Not sure if these will work for me. Which ones did you folks use?
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Offline cmotodad

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Re: 98 KX 500 Hard clutch pull
« Reply #11 on: September 15, 2014, 05:19:12 AM »
If you search clutch arm you see will the posts down a few.
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Offline sandblaster

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Re: 98 KX 500 Hard clutch pull
« Reply #12 on: September 15, 2014, 05:38:42 AM »
Thanks to Motorrad's great idea I made mine...

http://www.oem-cycle.com/forum/viewtopic.php?f=40&t=107
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Motorrad

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Re: 98 KX 500 Hard clutch pull
« Reply #13 on: September 15, 2014, 12:16:43 PM »
Quote from: sandblaster on September 15, 2014, 05:38:42 AM
Thanks to Motorrad's great idea I made mine...

http://www.oem-cycle.com/forum/viewtopic.php?f=40&t=107

Should note on your arm you were dumb and had to grind yours.    If you do it right no need to grind
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Offline sandblaster

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Re: 98 KX 500 Hard clutch pull
« Reply #14 on: September 15, 2014, 01:17:34 PM »
Of course I'm dumb.... I was born with half a brain...
And I couldn't weld if my life depended on it.
On the other hand I stole your idea and finished mine before you finished yours....  :-o
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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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