Clutch release arm extention

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mrmojorisin
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Clutch release arm extention

Post by mrmojorisin »

Has anyone welded an extension onto their clutch release arm? I've seen something about Jeff fredette advising this. Just curious what a good length to add on is.
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Re: Clutch release arm extention

Post by Dan 250sr »

Ebay sells a clutch easy pull. Little box goes between clutch lever and cable. There also selling hydraulic slave cylinders that replace the cable. I'd like to convert mine to hydraulic to make it easier.. if you lengthen arm you would need to use more clutch lever travel
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Re: Clutch release arm extention

Post by doakley »

I thought about it but went with a Magura hydraulic system, before I went to the autoclutch that is.
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Re: Clutch release arm extention

Post by SS109 »

Don't buy the clutch easy pull box. I have one that was given to me. I tried it and it sucks. It makes it easier but won't fully disengage the clutch. The only two real options are going hydraulic conversion or doing the actuator arm extension. IIRC, their is a KX125 actuator arm (remember, the KDX is based of the KX125) that drops right in that is longer.
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Re: Clutch release arm extention

Post by Dan 250sr »

What you gain you loose elsewhere. Hydraulic if it can be done, pit bike parts are as cheap as chips often see master cylinders ect on Ebay. Not sure what quality you will get.. I'm thinking about it..
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Re: Clutch release arm extention

Post by Dan 250sr »

doakley wrote: 06:23 pm Mar 21 2019 I thought about it but went with a Magura hydraulic system, before I went to the autoclutch that is.
Could you use auto clutch in traffic or around town ?
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Re: Clutch release arm extention

Post by Dan 250sr »

Dan 250sr wrote: 11:20 am Mar 23 2019
doakley wrote: 06:23 pm Mar 21 2019 I thought about it but went with a Magura hydraulic system, before I went to the autoclutch that is.
Could you use auto clutch in traffic or around town ?
Or do you have to set of with rear wheel on fire ? :grin:
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Re: Clutch release arm extention

Post by Glenn »

I'll second the motion of not buying the easy clutch. I bought one about 10 yrs ago for a big four stroke with heavy duty clutch springs. I snapped the easy clutch cable,If I remember correctly .it had a really weird feel to it also. I took out the heavy clutch springs and went back to normal set up and kept in the Barnett plates.
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Re: Clutch release arm extention

Post by Suzy America »

Hey guys :) New on the forum, just picked up a '99 KDX220R recently.

I'm casting votes for the actuator arm extension. My other bike (Honda CRF250L) has got a super light pull hydro clutch that cost all of around $45 to make. The essential steps were to add an extension to the actuator arm (1/8" extruded aluminum stock), get rid of the stock cable clutch and replace with generic Fleabay pit bike type, and add a long spring assist going straight to a chain attached to the actuator arm.

The only downside to this setup is that it narrows the angle of actuator movement. So when the engine has gotten properly hot (40+ minutes of trail riding) the clutch plates have expanded somewhat and it's harder to get into neutral. When that happens, I just unhook the chain from the end of that spring and move it up 4 notches. Then it's a buttery soft 1-finger pull that you can ride all day long, but which still has full clutch plate contact when the clutch is all the way out. I don't have a video up about this mod, but I can make one if people are interested.

I'm already partway through the same mod to the KDX. It has everything but the spring assist.
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Re: Clutch release arm extention

Post by 6 Riders »

I used the kx 125 clutch arm. It works very well.
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Re: Clutch release arm extention

Post by rexemouse »

I just did this mod. Extended about 5/8". Pull is noticably easier and the engagement feels alot smoother. Haven't noticed any clutch drag or difficulty starting in gear.

A longer lever achieves the same thing, but I like ASV levers which are on the shorter side, so this mod works well for me.

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Re: Clutch release arm extention

Post by John_S »

What year is the KX actuator from? Is it a direct bolt on or is there a little work involved?
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Re: Clutch release arm extention

Post by GATOROC »

I'm definitely interested in this as well. Hopefully it's an easy mod!
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Re: Clutch release arm extention

Post by John_S »

I found this thread. He used an 89 arm and was happy with it. When you look on Partzilla the part number changes pretty much every year in the late 80's early 90's so its hard to say what other years will work.

viewtopic.php?f=86&t=18581
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Re: Clutch release arm extention

Post by doakley »

Dan 250sr wrote: 11:23 am Mar 23 2019
Dan 250sr wrote: 11:20 am Mar 23 2019
doakley wrote: 06:23 pm Mar 21 2019 I thought about it but went with a Magura hydraulic system, before I went to the autoclutch that is.
Could you use auto clutch in traffic or around town ?
Or do you have to set of with rear wheel on fire ? :grin:
Autoclutch will work fine on the street.
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Re: Clutch release arm extention

Post by ericr »

John_S wrote: 01:16 pm Apr 08 2019 I found this thread. He used an 89 arm and was happy with it. When you look on Partzilla the part number changes pretty much every year in the late 80's early 90's so its hard to say what other years will work.

viewtopic.php?f=86&t=18581
I bought an '89 and it didn't fit. Nobody seems to have the p/n that actually fits. Here's another thread on the subject... viewtopic.php?f=86&t=23404
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Re: Clutch release arm extention

Post by John_S »

Eric I found one on eBay for a 93. I bought it but have no idea when I'll get around to trying it. I' don't know if you have dimensions of what would work but I'll measure it if it helps at all. Maybe someone has an H series one out of their bike that they can reference.
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Re: Clutch release arm extention

Post by John_S »

Listed for a 93 KX 125
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Re: Clutch release arm extention

Post by John_S »

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

I wish I had more time to install but with everything going on I'm trying to work as much as I can.
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Re: Clutch release arm extention

Post by SS109 »

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.
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