Clutch lever play vanishes

stephen · 11-01-2005

Hi all,

I've got a new KLE 500 and I've noticed two strange things regarding the clutch lever play. Firstly, I set the play to approx 1-2 mm when the oil is cold, bike standing in neutral, bars pointing straight ahead. However, as I ride the bike and the oil gets hotter (I guess), the play increases enormously, up to about 5 mm, actually making it difficult to change gears when the engine is hot. Also, in 4th gear, as I apply a load on the engine, all play in the clutch lever is taken up and the lever goes taught (even when there is stacks of play as mentioned above), if I close the throttle, the play returns, open it up, play is taken up again - but only in 4th.

Anyone come across anything like this before?

Cheers
steve

bluestringer · 11-01-2005

Hey Stephen, welcome. I have the same problem on my 800, the play gets tighter as I pick up speed, to the point where at highway speed I have to give the lever a pull to bring the play back. I have not figured out the problem yet. I have lubed the cable and made adjustments at the lever, mid adjuster and at the clutch housing, still no help. If I figure it out, I will let you know.

*ispeed77* · 11-01-2005

well, i am no mechanic, but i would think that since you are referencing the engine temp then maybe that has something to do with it. maybe when the oil starts to heat up, the clutch plates release a little more, adding play to the cable. you may need to set the cable tension with the engine warm, but that could also cause a problem. maybe post this question in the mechanics section, you should be able to get a more knowledgeable answer than mine in there

oh yeah, welcome to the forum

11-01-2005	#1 (permalink)
stephen Newbie Join Date: Oct 2005 Posts: 3	Clutch lever play vanishes Hi all, I've got a new KLE 500 and I've noticed two strange things regarding the clutch lever play. Firstly, I set the play to approx 1-2 mm when the oil is cold, bike standing in neutral, bars pointing straight ahead. However, as I ride the bike and the oil gets hotter (I guess), the play increases enormously, up to about 5 mm, actually making it difficult to change gears when the engine is hot. Also, in 4th gear, as I apply a load on the engine, all play in the clutch lever is taken up and the lever goes taught (even when there is stacks of play as mentioned above), if I close the throttle, the play returns, open it up, play is taken up again - but only in 4th. Anyone come across anything like this before? Cheers steve

11-01-2005	#2 (permalink)
bluestringer Rebel Rider BTK Expert Join Date: Jul 2004 Location: Albany, Georgia Posts: 3,445	Hey Stephen, welcome. I have the same problem on my 800, the play gets tighter as I pick up speed, to the point where at highway speed I have to give the lever a pull to bring the play back. I have not figured out the problem yet. I have lubed the cable and made adjustments at the lever, mid adjuster and at the clutch housing, still no help. If I figure it out, I will let you know. __________________ ..... bluestringer 2005 Vulcan 1500 Classic FI V&H Longshots VROC #13910 GAVROC #159

11-01-2005	#3 (permalink)
ispeed77 RIP Deron Harden :-( Extreme Forum Supporter Join Date: Sep 2004 Location: Gardner, MA Posts: 32,533	well, i am no mechanic, but i would think that since you are referencing the engine temp then maybe that has something to do with it. maybe when the oil starts to heat up, the clutch plates release a little more, adding play to the cable. you may need to set the cable tension with the engine warm, but that could also cause a problem. maybe post this question in the mechanics section, you should be able to get a more knowledgeable answer than mine in there oh yeah, welcome to the forum __________________ David - Moderator 2002 Suzuki DRZ400 2003 1500 Meanie, scraping pipes and frame :-) In loving memory of Deron Harden, forever in our thoughts :-(

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