Clutch release arm extention

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John_S
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Re: Clutch release arm extention

Post by John_S »

SS109 wrote: 03:44 pm Dec 12 2020
John_S wrote: 11:03 am Mar 28 2020 I forgot the length of the skinny middle part of the shaft. That would be 106.37 - 25.16 - 22.01 - 10.06 = 49.14
Just curious if you ever tried the '93 KX125 clutch actuator. I would love to have a definitive working part number for members, including myself, to go on.
Hi SS, sorry I've been out of the loop for a few months and haven't wrenched on the bike. I broke my right hand and ring finger pretty bad at work back in July. That and it sprained my wrist and hurt my elbow. It sucked! I took the bike out last night for a short run and feel like I'm ready to plan a day of riding. The stamina and strength are still down but its doing great considering how much it hurt for a while there.
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Re: Clutch release arm extention

Post by KDXGarage »

Congrats on healing up!
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Re: Clutch release arm extention

Post by SS109 »

Ouch! Hope you heal up 100%.
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Re: Clutch release arm extention

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Thank you guys! I appreciate it!
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Re: Clutch release arm extention

Post by John_S »

SS109 wrote: 08:56 pm Dec 23 2020 Ouch! Hope you heal up 100%.
I’m all healed up and have been riding the last few weekends, thankfully!! I installed the release lever. The one I bought listed it for a 93 Kx125 on eBay so I’m taking the sellers word on the year. I used my original spring and washer and it was a direct swap. Before I swapped it i took a digital luggage scale and checked the pull so I’d have a measurable difference. I put the nylon strap around the very end of the clutch lever by the ball and pulled slowly straight back to toward the grip. 5 pulls and it consistently saw 19.2 pounds by the time it got to the grip. I’m not sure how that number works but my clutch definitely didn’t feel like 20 pound finger curls. I would say it was a fairly easy clutch pull to begin with. I’ve used the same method to check my torque wrench from 15 to 100 pounds and it’s always right there within a pound. It’s not the easiest thing to do slowly with a digital scale on the clutch or torque wrench because if you pull too fast it can spike the number.

After the install it consistently read 10.8 pounds and feels like a kids bike clutch of a showroom bike. For reference it has an MSR AOF clutch perch and lever with OEM clutch springs with low hours. I didn’t change anything except the arm and didn’t lube the cable in between. I thought I would have to loosen the clutch cable since this arm is longer but I had to tighten the barrel a couple turns to take out the slack. The clutch engagement/release point feel exactly the same.
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Re: Clutch release arm extention

Post by SS109 »

Happy to hear you're healed up and back out riding!

John, thanks so much for the update and info! You rock! :supz:
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Re: Clutch release arm extention

Post by KDXGarage »

Thanks for the info. Keep riding!
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Re: Clutch release arm extention

Post by GATOROC »

Great information John, and glad you are able to get back on the bike again! This has been a mod I've been wanting to do for a while now, so hopefully I can get motivated to do it one of these days. :wink:
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Re: Clutch release arm extention

Post by John_S »

Thank you guys. I remember the main reason I didn't do it for so long. I don't know the part names but the top piece that swivels that the cable goes into had a lot of play. After all this time I ended up unhooking the cable from the stock arm to check the play and it was the same, sloppy. Once the cable puts that little bit of tension on that part it keeps it from wiggling around. After checking the stock one again and now the new one with the cable in place, its a non issue. When I first bought it I thought it was worn out.
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Re: Clutch release arm extention

Post by ericr »

Thanks for figuring this out for us. That's amazing that you can cut clutch pull effort almost in half for way, way less $$$'s than a Magura.
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Re: Clutch release arm extention

Post by John_S »

I was just browsing eBay and someone has a 93 kx125 clutch actuator for $35. The KDX spring and washer swap onto the new piece
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Re: Clutch release arm extention

Post by MoonStomper »

Can anyone think of a reason the actuator from a 2007 KLX 250 #13236-1259 won’t work?

My original has worn enough to let oil leak past the seal in the cover. Plus I’d like to lighten the clutch pull appreciably.
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Re: Clutch release arm extention

Post by bufftester »

That p/n is for the E-series bike as well as the KLX250/300. It may work, but I have not seen anyone try it or compare them. Many times Kawi rolled a part number with a model change even though the part didn't change, so if it does work it would be a boon.

FYI the part number it replaces (13236-0158) is the part number for the 2020-2022 KLX300 so if it does fit that part is still being manufactured.
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Re: Clutch release arm extention

Post by KDXGarage »

MoonStomper wrote: 07:17 pm Oct 30 2021 Can anyone think of a reason the actuator from a 2007 KLX 250 #13236-1259 won’t work?

My original has worn enough to let oil leak past the seal in the cover. Plus I’d like to lighten the clutch pull appreciably.
viewtopic.php?f=77&t=25094&p=216540&hil ... ch#p216540

might apply, not sure
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Re: Clutch release arm extention

Post by MoonStomper »

Think I’ll order one from RMATVMC and try it out. I also noticed that the needle bearings and oil seals my H model uses are the same as the 2007 KLX, so those diameters must be the same. What’s interesting to me is that some bikes used one needle bearing and others utilized a pair of them.

Also, in some parts diagrams with this style arm, they didn’t show or list the spring and washer… ?

During my last visit with Jeff Fredette, he mentioned modifying my arm so that it was longer to gain the lighter pull. But with the wear mine has at the seal allowing oil to pass I would rather just get a fresh actuator that’s already redesigned. He did give me a thin washer to lay on top of the seal and that is effective for creating better sealing… it raises the worn groove above the seal.
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Re: Clutch release arm extention

Post by KDXGarage »

Did the other guy not say it was longer?
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Re: Clutch release arm extention

Post by MoonStomper »

So that experiment was a FAIL. I ordered the newer clutch actuator used on the 2020 KLX 300R.

At first glance it appears identical. However, the length of the vertical rod is about .5” too short. This prevents installation. I tried with and without the return spring just to see, but the cover will not bolt back on.

The connector with the pivoting foot to the clutch cable end is longer, so it would have created the additional leverage we want.

Close examination of the parts diagram shows that this part doesn’t employ the return spring and washer found on the KDX clutch actuator. Thus, they used a shorter rod. So I sent it back.
Would love to see a modified piece where that arm is lengthened.
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Re: Clutch release arm extention

Post by John_S »

MoonStomper, a quick search on Ebay and I see there are 2 on there listed for a 93 KX125. Snatch one of them up for a direct swap.

Partzilla shows that part is the same on the 92 and 93 KX125. 91 and 94 are different part numbers
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Re: Clutch release arm extention

Post by SS109 »

Thanks for letting us know. Bummer it didn't work.
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Re: Clutch release arm extention

Post by MoonStomper »

Thanks for the heads up on the eBay pieces. I looked them up, but they both look like they have excessive wear below the spring. Actually worse than mine which already leaks oil all over my clutch cover. I may just try to have my buddy weld 10mm of length onto the actuator I have.
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