Adventure Bike Rider Forum

Hi all,

I know this has probably been done before but I'm styuggling to understand an issue which I'm sure is common. The internet isn't giving me the answers I need.

I have a XR125L and I'm struggling to get the clutch to improve to a decent standard. It appeared worn with the bite being right at the end of the release. Yesterday I chenged the clutch plate expecting them to be worn and while they were a bit the new ones haven't really changed the feel.
I soaked the new ones before installing and copied the plate order and it looks right enough.

I've adjusted the cable which makes little difference and I'm now out of ideas, what am I missing here please?

Cheers

Bren

Greetings Brenhden,

I am not familiar with the clutch of your bike but just as an idea have you inspected for wear/damage and measured the free length of your clutch coil springs. There may be a reference figure for free length and for compression under a given clamping load.

TTFN

Hugh.

2nd that Hugh.

Always check the springs first

Thanks guys,

Really wish I'd asked before opening her up yesterday.

While I'm here, in order to get to the basket you have to take the oil filter out and it's geared to the clutch and spins when you try and undo it. Yesterday I used a bit of wood to wedge it but it didn't work well, is there a good technique for holding this while I undo it?

Cheers

Bren

Another for the springs. check they are are with in spec also make sure all are torqued down evenly.
worn clutch push rod.
Does your clutch have the metal rings are these the right way round, on KTM the chamfered edge to the front except I think one which is the other way round.
Is it Hydraulic or cable if cable is worn could possibly cause drag on sleeve,
IS there an oil jet as in the KTM these can become blocked and cause issues.

Hold clutch
https://www.ebay.co.uk/itm/KTM-125-150- ... OSwHfxeDhW~


sometomes putting bike into top gear and have some hold brake and block rear wheel might do.

Locking engine to TDC with appropriate tool

zimtim wrote: ↑Mon Jul 13, 2020 10:46 am Hold clutch
https://www.ebay.co.uk/itm/KTM-125-150- ... OSwHfxeDhW~


sometomes putting bike into top gear and have some hold brake and block rear wheel might do.

Locking engine to TDC with appropriate tool

Thanks Zimtim, I'm embarrassed I didn't think of that...

zimtim wrote: ↑Mon Jul 13, 2020 10:46 am Hold clutch
https://www.ebay.co.uk/itm/KTM-125-150- ... OSwHfxeDhW~


sometomes putting bike into top gear and have some hold brake and block rear wheel might do.

Locking engine to TDC with appropriate tool

Try everything Zim has suggested (lock rear wheel, top gear, bind the rear brake on etc), but some people also jam a copper coin (or maybe an old 2p piece) in the gears (where your red arrow ends). Any flat bit of metal of a softer alloy than the gears.

zimtim wrote: ↑Mon Jul 13, 2020 10:43 am Another for the springs. check they are are with in spec also make sure all are torqued down evenly.
worn clutch push rod.
Does your clutch have the metal rings are these the right way round, on KTM the chamfered edge to the front except I think one which is the other way round.
Is it Hydraulic or cable if cable is worn could possibly cause drag on sleeve,
IS there an oil jet as in the KTM these can become blocked and cause issues.

Alas I can't find a workshop manual. Cable seems new but thats a cheap fix so I'll swap that out. It has rings but they seem the same both sides. I've got them bolted in evenly best I can.

DIdn't spot an oil jet, but I guess the weird spinning oil filter feeds the clutch...