washer for clutch pusher + clutch wear question

Got questions? We got answers....
Post Reply
chadr
Supporting Member
Posts: 130
Joined: 12:03 am Dec 14 2010
Country: US
Location: Tampa, FL

washer for clutch pusher + clutch wear question

Post by chadr »

My bike was missing the clutch pusher washer

Image

When I was in there doing some other work I installed a new one and found the clutch would not engage even with the cable slack adjustment set to the max (both adjustment points). I had to take the cover back off to remove the washer. The cable adjustments are almost at the maximum again so I plan to install new clutch discs and plates soon.

I'm sure my clutch is very worn out now, but is there any problem running the clutch all the way until it just doesn't grip anymore? I didn't measure the thickness of the discs when I had it apart so I don't know if they are beyond the wear limit.

If I didn't remove the washer I would have had to replace the discs already. Is this washer meant to be removed as the clutch wears down?
1989 KDX 200
User avatar
rbates9
Supporting Member II
Supporting Member II
Posts: 3164
Joined: 06:07 pm Apr 27 2010
Country:
Location: UPSTATE New York

Post by rbates9 »

The washer is a shim. It is used to adjust the clutch arm on the clutch cover. There is a section in the book about it. They say you could have 0,1,or 2 in there.
chadr
Supporting Member
Posts: 130
Joined: 12:03 am Dec 14 2010
Country: US
Location: Tampa, FL

Post by chadr »

Thanks

Is there any problem running the clutch all the way until it just doesn't grip anymore
1989 KDX 200
User avatar
rbates9
Supporting Member II
Supporting Member II
Posts: 3164
Joined: 06:07 pm Apr 27 2010
Country:
Location: UPSTATE New York

Post by rbates9 »

That would be a personal choice. If it is still grabbing good I would run it Until I had some other indication that it was bad. It could also be that your clutch cable is stretched out and that might be where your adjustment went.
User avatar
Julien D
KDXRider.net
KDXRider.net
Posts: 5858
Joined: 07:53 pm Nov 07 2008
Country: USA
Contact:

Post by Julien D »

Get all you can out of it, for sure. Also, yes, check the cable as was wisely mentioned above. Clutch cables are cheap, might as well replace it before you go and spend on a clutch kit.
chadr
Supporting Member
Posts: 130
Joined: 12:03 am Dec 14 2010
Country: US
Location: Tampa, FL

Post by chadr »

Well, a stretched cable would actually work ok for me here. A cable with less slack will not allow the lever to go back as far as a stretched one would. I do have a new cable waiting to go in too once the clutch no longer holds. I'll run this clutch till the very end :)
1989 KDX 200
User avatar
rbates9
Supporting Member II
Supporting Member II
Posts: 3164
Joined: 06:07 pm Apr 27 2010
Country:
Location: UPSTATE New York

Post by rbates9 »

If your out of adjustment room how would a stretched cable help?
chadr
Supporting Member
Posts: 130
Joined: 12:03 am Dec 14 2010
Country: US
Location: Tampa, FL

Post by chadr »

i really doubt the cable stretches much, but my perch and in line adjustments are nearly all the way in to allow the cable to have the most slack possible. There is no way to get more slack. I don't know why the adjustment needs to be a the extreme end but I assumed it was the clutch wear. As the clutch wears down I think you have to add slack to the cable to get the freeplay at the lever back to where it was (~2-3mm). Is that right?

It sure is much easier to adjust it then discuss adjusting it. This gets confusing.
1989 KDX 200
User avatar
kdxquebec
Supporting Member II
Supporting Member II
Posts: 1255
Joined: 07:18 am Nov 24 2004
Country:
Location: Québec:North Pole
Contact:

Post by kdxquebec »

My '89 does not have that washer. My factory manual says '' re-install washer if provided''

I will check tonight to confirm but I'm almost sure :grin:
'89 KDX 198cc '03 Gasgas Ec250 '13 Husaberg Te300
*CANADA* LEADING THE WORLD IN BEING JUST NORTH OF THE UNITED STATES.
Image
User avatar
Coop
Supporting Member
Posts: 180
Joined: 03:52 pm Sep 24 2010
Country:
Location: Acme, PA

Post by Coop »

Those shims are to adjust the lever angle. If it is more than 90° add a shim, less than 80° remove one (if present at all). Any more than two shims and you need to check your plate thickness.
"Twenty years from now, you will be more disappointed by the things that you didn't do than by the ones you did do" - Mark Twain

2003 KDX200
engybenjy
Member
Posts: 35
Joined: 03:24 pm Mar 14 2010
Country:

Post by engybenjy »

My lever doesnt move more than 45 degrees......
Gaffa Tape is like the Force. It has a Dark Side, A Light Side and it binds the universe together.
And nothing says bad workmanship like wrinkles in the kidnap tape!!!
dfeckel
Platinum Member
Platinum Member
Posts: 644
Joined: 07:46 am Nov 09 2009
Country:

Post by dfeckel »

I think the angle being measured is between the cable and the arm.
David Eckel
User avatar
rbates9
Supporting Member II
Supporting Member II
Posts: 3164
Joined: 06:07 pm Apr 27 2010
Country:
Location: UPSTATE New York

Post by rbates9 »

Yup
Post Reply