Clutch release arm extention

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John_S
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Re: Clutch release arm extention

Post by John_S »

I went riding Sunday and have the KX actuator and stock clutch springs. I’ve ridden many times with it and it still surprises me how good it is. It’s the lightest clutch pull I’ve ever felt and wouldn’t trade it for a brand new hydraulic clutch. It’s the best $35 mod.
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Re: Clutch release arm extention

Post by Goat »

It is, now. Feels like sweetness. Mini bike trails in the dark are good test but needs some gnar.
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billie_morini
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Re: Clutch release arm extention

Post by billie_morini »

SS109, John_S, &/or Moonstomper,
Will one of you reveal how to replace the actuator arm, please? Not looking for extensive step-by-step details. Just curious to know if clutch cover requires removal, or it's simply pull existing arm upward and slide replacement in, or something else. Thx in advance,
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Re: Clutch release arm extention

Post by John_S »

You have to pull the clutch cover to replace the arm. Then it pulls up and out and the new one right back in. If you lean the bike over most of the way you don’t need to drain the oil. Have a new clutch cover gasket on hand if yours tears. If you’re installing a new gasket apply a light coat of grease to both sides then you can take it off multiple times and the gasket won’t stick.
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Re: Clutch release arm extention

Post by DonnyV »

Yeah just got to find one, you guys bought them all up lol I keep checking but no luck yet
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Re: Clutch release arm extention

Post by MoonStomper »

I got mine from Fredette. He said he’s needing to talk with Kawasaki about producing some more, along with some other crucial parts. He just got back from the ISDE in France and packed up his ‘41 Harley to ride to Santa Monica in a Cannonball ride. Probably will be hard to reach till the end of the month.
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billie_morini
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Re: Clutch release arm extention

Post by billie_morini »

John_S wrote on 9/19/2022, "You have to pull the clutch cover to replace the arm. "

THANK YOU!
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Re: Clutch release arm extention

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SS109
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Re: Clutch release arm extention

Post by SS109 »

billie_morini wrote: 12:26 am Sep 28 2022 1993 KX 125 Clutch Actuator Arm!

https://www.ebay.com/itm/225091624228?h ... R_DuyKjwYA

:boogie:
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Re: Clutch release arm extention

Post by Goat »

Excellent use of your next $30 !
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billie_morini
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Re: Clutch release arm extention

Post by billie_morini »

Goat wrote: 05:57 pm Sep 29 2022 Excellent use of your next $30 !
Goat, I obtained 1 a few weeks prior. Was alerting others. This 1 went fast.

Work & illness prevented installation for me. Soon.
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Re: Clutch release arm extention

Post by KDXGarage »

Nice avatar!
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
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billie_morini
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Re: Clutch release arm extention

Post by billie_morini »

KDXGarage wrote: 01:53 am Oct 07 2022 Nice avatar!
Thanks much, KDXGarage. Shows and Old Man can learn a new trick. Although, my 20-something nephew taught me how.
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billie_morini
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Re: Clutch release arm extention

Post by billie_morini »

I’m conducting a simple test that may interest some of our forum members.

About a month ago, I purchased a used KDX 125 clutch actuator arm from an ebay vendor. Like many of these used parts, there were grooves worn into the top end of the cylindrical arm shaft. When grooves are present, there is concern for potential oil leak from the arm shaft oil seal located on the topside of the clutch cover.

Normally with something like this, I’d fill the grooves with wire weld and then use a lathe to smooth the weld material to the original shaft diameter. However, its known that not all forum members have access to welding equipment. So, I thought I’d fill the grooves with something that is available to most forum members.

The grooves in the photos below are filled with JB KwikWeld Quick Setting Steel Reinforced Epoxy. Even though KwikWeld sets rapidly, the epoxy was allowed to cure for 24 hours following each application prior to sanding. The first application was the most extensive and to cure this application very thoroughly, the arm shaft was placed in hot, direct sunshine.

The applied epoxy required smoothing. Some of the highest bumps were knocked down using Oatey Open Mesh Abrasive A-180. This abrasive was used carefully to avoid digging epoxy from the grooves and also avoid scratching the arm shaft. The abrasive was followed by 600 wet-dry sandpaper (used dry). This was followed by 220 wet-dry sand paper (used dry). A few tiny divots in the cured epoxy were exposed and, therefore, the epoxy was not completely smooth. More Kwikset epoxy was mixed, applied to the divots, and allowed to cure for 24 hours. The second epoxy application was smoothed with 600 and 220 wet-dry sandpaper (used dry). When satisfied that applied epoxy was adequately smooth and excess epoxy outside the grooves was removed, the upper shaft, including smoothed epoxy, was sanded with 1500 wet-dry sandpaper (used dry).

All sanding was done by hand with lots of patience. Afterall, I’m curious to see how well this works and gave it the best potential. Following any sanding, it was necessary for me to examine the result with a 10x (power) jeweler’s hand loop (e.g., geologist’s hand lens). Hopefully, forum readers possess better eyesight than me.

It’s necessary to go on a week-long business trip beginning tomorrow (Monday). So, clutch actuator arm installation is delayed at least a week. Installation problems are not anticipated. Effective oil seal is anticipated, at least in initial used. The true objective is to see how well the JB KwikWeld Quick Setting Steel Reinforced Epoxy performs in this specific application. Potential future report in 6 to 12 months following installation.
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Slick_Nick
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Re: Clutch release arm extention

Post by Slick_Nick »

Good job, but honestly I would have welded it. I fear that JB weld will wear through quickly, as grit gets into the seal and wears it down.
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billie_morini
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Re: Clutch release arm extention

Post by billie_morini »

I concur with you, Nick. Normally, I would. However, not all forum members have welding at their disposal. I'm using epoxy to see if it can help these specific forum members.
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SS109
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Re: Clutch release arm extention

Post by SS109 »

Interesting. I do agree with Nick but am looking forward to the results.
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Re: Clutch release arm extention

Post by KDXGarage »

J-B Welding is the only type of welding I know how to do! I am curious to see how it turns out.
Thank you for participating on kdxrider.net. :bravo:
To post pictures from a device: viewtopic.php?f=88&t=24128
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MoonStomper
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Re: Clutch release arm extention

Post by MoonStomper »

That’s a project I thought of when dealing with the actuator issues initially, but didn’t attempt. Looking forward to seeing how the long term test goes. Maybe some Redn’Tacky will help the longevity?

Great job by the way, it looks super legit!
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Let the good times ROLL!!!!!!!!!!!!!!!!
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doakley
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Re: Clutch release arm extention

Post by doakley »

Just a little follow up note. I got a chance to check out Moonstomper's KDX with the extended clutch arm last weekend. I can tell you it is the lightest, sweetesst pulling clutch I think I've ever pulled. I did not ride the bike (I would never ask to ride someone's bike before a race start), but it was definitely sweet!
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