Clutch adjustment

[DRGSin393]

Hey guys, I have a question for ya. Just put in a whole Hinson clutch setup with new plates and my clutch lever has a lot of play. When I adjust it at the lever, the adjustment "screw" is almost all the way out. Do I need to adjust it at the motor end? Is there another adjustment that I'm missing? Thanks in advance for the help.

[MXFastGuy]

There's a cable adjustment just downstream from your lever. It's for major adjustments, the one on your perch is for fine adjustments.

In case you didn't know, btw, it's normal to get lots more free play after installing new plates b/c the clutch stack is thicker.

[DRGSin393]

Thanks for the info. I didnt know about the excess clutch play after a change. I guess I shouldve thought it through.

[Keetoman393]

Originally Posted by MXFastGuy

There's a cable adjustment just downstream from your lever. It's for major adjustments, the one on your perch is for fine adjustments.

In case you didn't know, btw, it's normal to get lots more free play after installing new plates b/c the clutch stack is thicker.

Great information. Welcome to the both of you!

[Florida 393]

Doc,
Good advice on the adjustment by MXFastGuy . I instaled a complete Hinson ste up (Basket, center hub and pressure plate with EBC plates) in my '02 426. That clutch just hooks up solid. I got used to the stronger springs and now it is a joy. If all those privateers and factories use this set up I figured it was good enough for me. I had to buy a piece at a time with the cost but it was worth the effort.

Now I just need a Magura hydraulic clutch lever setup

Bill

[MXFastGuy]

I am also planning on a Magura unit. I used one on a '00 CR250 and it worked great once I made some shims.

Let me know about your luck with the EBC plates. I get OEM fibers b/c they don't seem to swell like the aftermarkets, but they cost bookoo $$$$!

[Florida 393]

MXFastGuy,
I have had no problems with swelling of the fiber plates at all . I soaked both the fiber and metal plates on Yamalube 4R (the oil I use, spare me the sermons on oil choice all you other guys that want to convert me: ) before I installed the assembly. So far so good. I can hammer the throttle on release and have no problems. I am a clutchless shifter anyway so I have few problems.

Bill

[DRGSin393]

My sons' KTMs have Magura clutches and I've been wanting to convert for a couple of years now. I've heard of other people having difficulties adjusting them and making them work right, so I haven't taken the plunge. So hurry up and do it! lol It's good to hear u haven't had any probs with the EBC plates. I also only use OEM's and the pricing's outrageous.

[Florida 393]

Doc,
The EBC clutch plates were the least expensive when I was buying the components. I saw where KTM is switching to a Brembe clutch unit so they can avoid the mineral oil hassle. Maybe that is worth looking in to.

Bill

[DRGSin393]

Hmmm. I'll get on KTMtalk and see what everyone says about Brembe (sp?). Can you imagine not having to adjust a clutch? Im getting goosebumps! lol

[MXFastGuy]

Originally Posted by Florida 393

...Now I just need a Magura hydraulic clutch lever setup

Bill

Bill, did you get a Magura yet?

Mine just arrived today but my bike's in pieces, it'll be 2-3 wks until I can ride again. I was pleasantly surprised when I opened the box, it was the new Gen II with carbon hose and new style slave with bleeder fitting. I didn't think they had the new style for this bike yet, so it was a nice surprise. The build seems tons better than the one I had ~5 yrs ago on a CR250.

I fitted it on the engine (not in frame ) and a loose pair of bars to try it out. Fitment is top-notch. I measured 9.5mm of clutch arm actuation, whereas the cable setup yielded 11mm. Hopefully that won't be a problem, I remember on my CR when I put in new plates I had trouble getting complete disengagement. With new plates the actuation point seems to generally move-in towards the bar (regardless of cable or hydro).

So far it looks good, I'm anxious to try it out!

[Florida 393]

MXFG,
I didn't have any time to do anything moto related during December and January looks grim due to work ramping up big time too. I received an ASV clutch lever/perch and brake lever set for Christmas so I reckon I'll be waiting for a while now. The ASV system pulls nicely for a conventional setup. After reading your reply I may reevaluate my thoughts and look at a Magura system again.

I am still considering the Brembo (spelled it right this time Doc!) unit since it uses brake fluid instead of the mineral oil in the Magura set-up. I haven't ruled the Magura out and I checked with ASV on a lever for that application. The KTM clutch lever will work fine if I get the Magura.

I am kind of holding off right now since I am seriously considering a KTM or an RM Suzuki and setting the bike up for Hare Scrambles and enduros (Yeah I am committing heresy by doing something other than MX: ) I will do some research on the KTM 400 EXC-G and SX 250 for a bit and the local Suzuki dealer is a good friend so I can get a left over RM 250 smoker at a good price. I see bark busters, skid plates, shark fins and an ICO computer in my future I fear, unless I can talk Monica into letting me keep the YZ 426F since it is long paid for .

Bill