Dear all,

I was having great difficulty with the force needed to operate the clutch. It was too stiff for me and and after 1 hour or so I was having cramps on my left hand.

Searching through the net I was unable to find a satisfactory solution and decided to go ahead with my own solution which was extending the clutch lever on the engine. It worked great for me and I wanted to share it with you guys. Please see the photos and let me know if you need any additional information. The only price you need to pay is to mention my name with the mod.

You can even aim for 70 mm as I saw it would be perfectly fine after I tried mine at 60mm. You will not believe how you did without this modification until now.

Best regards

Sedat Bilgebay

Attached Images

	Bilgebay clutch lever modification cr.jpg (174.0 KB, 2101 views)
	Bilgebay clutch lever modification_2cr.jpg (172.1 KB, 1712 views)

Great mod, do you find you have enough travel to make the clutch work?

I find that the standard lever still means that the bike drags the clutch, even with the Clutch adjusted up.

__________________
Colin
09 XTZ in Blue and its nearly Stanard.
My Mods - Peatbog rear rack

Well done, it is quite a smart way to fix that problem, in fact the longer the lever the lighter the action. Yet I am curious to understand if this was just a personal issue with you, that you have also encountered with other bikes as it is the first time I hear someone finding the XT's clutch too hard. Not being funny but how big is you hand?

Captmoto, I must admit that my hands are not that strong anymore after so many years of mouse driving in front of the computer. However, I am riding another bike which has a much lighter clutch. After the XT, I can tell you the other bike, which is a Honda, got even lighter which is an indication my hand growing stronger. Still I found the XT clutch intolerable. Besides there ara the hydraulic clutches on the market claiming a 20% increase in the force you apply to the lever so there must be a demand for this. My solution is offering a 50 % increase in the force you need to apply or 33 % less demand for force, ie instead of applying a 5kg force you only need 3.3 kgs.

Regards

Sedat

I am sure you will get used to the XT clutch. My hand/wrist was sore for a couple of weeks after moving to the XT from my DT125, but now it is fine and no problems at all with it. I have to operate the clutch with only two fingers and as the rest of my left hand is missing.

Hmm nice mod, Ive never considered the clutch to be hard for me! I only use four fingers at trafic lights or junctions for saftys sake and two for gear change on the move!
Well done though

Hi colros! Believe me there is no difference in the drag. I agree, when you engage the first gear it kicks the bike both with and without the modification. If you carefully check the lever photo I kept the original hole in place ( at 40mm) I have added another hole at 50mm and yet another at 60mm. I tried all three of them again and again to be on the safe side. No difference in that clunking at all. The clutch is functioning in a very narrow angle anyway, so this is not an issue. You have the usual recommended gap at the hand lever even at 60mm hole.

Hope this answers

Sure does, many thanks

I do find the Clutch can be heavy when in town. But my Left wrist has been broken in the past and I tore the ligaments in the Thumb. So not what you call a shining example.

Keep up the good work.

__________________
Colin
09 XTZ in Blue and its nearly Stanard.
My Mods - Peatbog rear rack

I think this could be a new mod that can be added to the list us XT boys and girls have designed/made

bilgebay mod

got a ring to it

__________________
Plough on

All ready in the modfication index.

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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
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My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946