Clutch release arm extention

[MoonStomper]

UPDATE… picked up a brand new in the package KDX clutch actuator from Fredette! I pulled out my old one for a side by side comparison - see pix. My buddy is going to weld a 3/8” extension on to the new one using the old one. Should have pix of it all later this week.

Also awaiting a new Streamline Reflex clutch perch/lever from RM. My clutch cable has less than a year on it, is freshly lubed and ready to go.

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You can really see the grooves worn into the old shaft allowing oil to bypass the clutch cover seal.

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[KDXGarage]

Wow. Part was ordered ten years ago next month.

Thanks for the pics of wear comparison.

[MoonStomper]

Happy day! Has taken awhile to get here, but it’s finally done. We welded 3/8ths” on and I painted the weld with some silver rattle can. Hoping to test ride and get a feel for the changes in the morning. On the stand the easier pull was apparent. The new lever is smoother too, the ball bearings feel nice and smooth. Installed a fresh oil seal and Kawasaki clutch cover gasket too. Looking forward to not smearing oil all over everything.

Old piece versus the extended new piece…

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New Streamline Pro Reflex Clutch Lever…

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Will update tomorrow after buttoning everything back up and testing her out.

[KDXGarage]

NICE!

Spoiler alert, he will report it is better. :-)

[MoonStomper]

With all the pieces in place (at 11:30 pm!) I had to wait until this morning to shake her down. Immediately noticed the hydraulic clutch-like feel on the new lever, the actuator definitely lightens the pull in an appreciable amount too. However, after warming up and clicking in gear - when I released the buttery smooth lever nothing happened - which I sort of expected since I hadn’t adjusted the cable length yet.

So I figured I had her too short and cranked the cable adjuster to the extreme extended length. Fired, her up, clicked a gear, released the silky-smooth lever and NUTHiN’. Hmmm… I must be missing something, looking down at the actuator I could tell the arm wasn’t swung back properly. Somehow my cable was still too short to allow the actuator to disengage. Time to re-examine the assembly instructions on the new lever. After removing an un-needed cable housing extender from the lever I was able to make it work properly.

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This is not needed for my application.

[MoonStomper]

One last final tweak was required for this modification. The extra length of the modified foot ends up using all of your available clutch cable free play. I spoke with Jeff Fredette about this and he suggested creating a “slight dog leg” in the foot near the end. This would bring the cable head catch towards the cable and create the slack I needed.

By putting the piece in a soft jaws clamp and using a sawzall, a slit was cut about 4/5ths the width of the foot on the leading (forward) side, then gently tapped the end with a hammer to close the gap. This gave me 1/8” of forward reach, I decided I wanted just a little more so I carefully reopened the gap and using an abrasive cutting disc widened the cut to about twice the saw blade thickness. After closing the gap by tapping it shut again, welding the seam, and grinding it smooth I ended up with about a 1/4” of improvement.

While I had the opportunity, I used my Dremel to grind in a small groove for the spring hook to rest in just like the stock part originally had. After cleaning it up, I sprayed some silver paint to finish the job.

Testing this modification was extremely gratifying as I was able to introduce slack back into the cable at both the cable juncture and the lever to achieve the desired free play. My clutch feels as easy and smooth as a hydraulic and I’ll never need to bleed it.

[John_S]

Good to hear you got it just how you want it. I stopped by a dealership this week and was looking at a CRF 450 RX. Pulling the hydraulic clutch isn’t as easy or smooth as my KDX with the KX 125 actuator. It’s such a great modification.

[SS109]

I have a '93 KX125 arm on the way now. Can't wait to try it out.

[MoonStomper]

Saw an interview with Eli Tomac talking about how he prefers the cable clutch to the hydraulic ones. That’s interesting.

[Slick_Nick]

Saw an interview with Eli Tomac talking about how he prefers the cable clutch to the hydraulic ones. That’s interesting.

Not really. Every hydraulic clutch I’ve used, I’ve always preferred the feel of a cable clutch. It’s much more precise, especially on a motocross bike where you need that precise feel.

[SS109]

Same here. I like a cable clutch better myself. I've had two hydraulic clutch bikes, and ridden a bunch of others, and still prefer the cable. I just like being able to feel the engagement point a lot better. Hydraulic seems to dull that feeling.

[SS109]

I got my '92'-93 KX125 clutch actuator (Kawasaki OEM part# 13236-1230) and installed it today. I can confirm it was a straight drop in replacement for the stock KDX actuator and was a super simple swap. I measured that the KX125 actuator is about 8mm (give or take a little) longer than the stock KDX one. My clutch lever pull is now lighter than my buddy's '18 YZ250X and my '11 GasGas which has a hydraulic clutch! Such a simple and cheap mod I'm kicking myself for having not done it way sooner. My first ride will be on it tomorrow and hopefully it makes the clutch more progressive and less of a light switch.

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[Kawibunga]

Great info! may have to try that myself, or potentially even try to build one.......... I actaully have a hydraulic kit for my KDX but have not mounted it yet. Might try this on one machine, and the hydraulic one another and compare apples to apples..........

[John_S]

That’s great news SS.

[MoonStomper]

Where did you find the new KX125 actuator? Also, very curious on if there’s a way to prevent or at least delay the grooving that occurs where the actuator exits the cover at the seal. Eventually causes an oil leak.

[SS109]

Where did you find the new KX125 actuator? Also, very curious on if there’s a way to prevent or at least delay the grooving that occurs where the actuator exits the cover at the seal. Eventually causes an oil leak.

Got it off ebay for under $30 shipped. There is another one on there right now for about the same price. Don't know how to stop the groove from wearing in. Maybe a really thin steel or bronze replaceable sleeve?

[SS109]

Rode yesterday with the KX actuator... O...M...G!!! I can't believe what a difference it makes! I'm truly surprised those of you that have done this mod, or similar, haven't been raving about it! Who needs a hydraulic clutch when this mod is so much simpler and cheaper and works just as good?

It turned my clutch in to a true one finger pull, clutch action feels much smoother, and it widened my clutch engagement at the lever. The pull is lighter than my GasGas with hydraulic clutch and my buddy's YZ250X. It took a few to adjust to the new engagement but once I did, oh yeah! I could rocket out of corners way quicker since I was keeping wheel spin under control. I also noticed my clutch hand never got tired and I never resorted to using 3 or four fingers when holding it at a stop for a few.

I would almost say this is a Top 5 mod IMO. It really was that much of a game changer for me.

[Goat]

This just sounds too good to be true! But for $30, how could I resist. eBay delivery arrived, yesterday.

[MoonStomper]

Is it in yet? (That’s what she said!)

[SS109]

Awesome! You're going to love it.