Advice for Cable Clutch Upgrade

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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DeKay
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Advice for Cable Clutch Upgrade

Post by DeKay » 03:50 pm Mar 22 2020

Hi There anyone out there got advice for the best perch and clutch cable upgrade on the OEM for my sons 2005 KDX200. He has small hands and like all of us would like the easiest pull on the clutch as practiable.

:boogie:

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Kdxfan4130
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Re: Advice for Cable Clutch Upgrade

Post by Kdxfan4130 » 05:46 pm Mar 22 2020

Wr450f Yamahas have a tremendously tough clutch lever effort, I rode a friends that had the lever/cable end location redrilled and it wasn’t bad at all. Lengthening the clutch arm and a ratio reducer also do the trick
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Restore rather than replace

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doakley
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Re: Advice for Cable Clutch Upgrade

Post by doakley » 06:19 pm Mar 22 2020

I didn't know about this Outlaw Racing product but it looks interesting and is cheap enough to be worth a try. I switched to a Magura hydraulic system AR first and loved it. Ultimately I ended up putting in an an EMF Autoclutch and just eliminating the clutch lever. I had other reasons for wanting the autoclutch though. Not sure I would recommend it for a lung rider as it will keep him from learning proper clutch control.

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Re: Advice for Cable Clutch Upgrade

Post by SS109 » 10:00 pm Mar 22 2020

Trust me, don't waste your money on the Outlaw Racing system or any like it. Yes, technically it does work but it totally changes how your clutch feels at the lever. Expect to have to pull the clutch to the bars to get it to disengage the clutch and it might not even then. Tried one on my bike as it was given to me. I ripped it back off after my first ride with it. Just horrible.

Better mods are going with a high quality Motion Pro cable and lube it before installation. You can also install a clutch lever that has adjustable reach. Another mod, but can't remember from what year bike to use (search the forum here), is install a KX125 clutch actuator. Between the three it will make the clutch pull lighter and easier to reach. Also, make sure the clutch basket isn't notched as it can increase the strength to pull the clutch lever.

If you want to get really crazy, you can a Magura hydraulic clutch setup but it's a little pricey! https://www.rockymountainatvmc.com/part ... h-p?v=4169
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Kdxfan4130
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Re: Advice for Cable Clutch Upgrade

Post by Kdxfan4130 » 10:55 pm Mar 22 2020

doakley wrote:
06:19 pm Mar 22 2020
I didn't know about this Outlaw Racing product but it looks interesting and is cheap enough to be worth a try. I switched to a Magura hydraulic system AR first and loved it. Ultimately I ended up putting in an an EMF Autoclutch and just eliminating the clutch lever. I had other reasons for wanting the autoclutch though. Not sure I would recommend it for a lung rider as it will keep him from learning proper clutch control.
I have a rekluse on my 450x and I really like it still getting to dump the clutch, but I’m too chicken to run a clake & remove the rear brake lever! Your the man!
I’ve never ran that Outlaw ratio changing device but lengthening the clutch arm and redrilling the lever does improve lever pull effort. Lever mod is cheap too, isn’t to complicated to perform.
Google ‘reduce clutch lever effort on a motorcycle’ multiple options pop up
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Re: Advice for Cable Clutch Upgrade

Post by ericr » 12:17 am Mar 23 2020

I recently bought a used beta xtrainer and found that for those bikes, people just shim the clutch pressure plate bolts with washers. This reduces the preload on the springs and makes clutch pull much easier. For them, 1.6mm of M6 washers is all it takes. It does so without any clutch slippage under load. I wonder if that's something that would work with our bikes too.
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Re: Advice for Cable Clutch Upgrade

Post by lizardfungus200 » 09:12 am Mar 23 2020

DeKay wrote:
03:50 pm Mar 22 2020
Hi There anyone out there got advice for the best perch and clutch cable upgrade on the OEM for my sons 2005 KDX200. He has small hands and like all of us would like the easiest pull on the clutch as practiable.

:boogie:
What I did was take out the small washer that goes in between the clutch pin and the bearing on the pressure plate. This made it a little easier with no problems
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Re: Advice for Cable Clutch Upgrade

Post by javjacob » 03:27 pm Mar 23 2020

Works Connection has the best perch/lever if you ask me. I have one on all 3 of my bikes. Also make sure the cable is good or replace the cable. If he is having a hard time with the KDX clutch he better start doing some hand strength work outs. The KDX clutch is easy.
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Re: Advice for Cable Clutch Upgrade

Post by SS109 » 05:47 pm Mar 23 2020

SS109 wrote:
10:00 pm Mar 22 2020
Trust me, don't waste your money on the Outlaw Racing system or any like it. Yes, technically it does work but it totally changes how your clutch feels at the lever. Expect to have to pull the clutch to the bars to get it to disengage the clutch and it might not even then. Tried one on my bike as it was given to me. I ripped it back off after my first ride with it. Just horrible.
I forgot to add another problem with this type of unit. It flops around like crazy smacking your bars and whatever else is close to it.
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Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue

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doakley
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Re: Advice for Cable Clutch Upgrade

Post by doakley » 08:00 pm Mar 23 2020

SS109 wrote:
05:47 pm Mar 23 2020
SS109 wrote:
10:00 pm Mar 22 2020
Trust me, don't waste your money on the Outlaw Racing system or any like it. Yes, technically it does work but it totally changes how your clutch feels at the lever. Expect to have to pull the clutch to the bars to get it to disengage the clutch and it might not even then. Tried one on my bike as it was given to me. I ripped it back off after my first ride with it. Just horrible.
I forgot to add another problem with this type of unit. It flops around like crazy smacking your bars and whatever else is close to it.
OK. I trust your experience. Sounds like junk! (It did seem too good to be true.)

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Re: Advice for Cable Clutch Upgrade

Post by GATOROC » 10:48 pm Mar 25 2020

Here's a link to some info on extending the clutch arm like SS109 mentioned above - Clutch release arm extension . I've been thinking about doing this mod, but just haven't gotten around to it since my clutch lever isn't too difficult to pull.
2000 KDX 220

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