Clutch springs

[Mike Hufnagel]

Are there any alternative springs for a 250 motor that I could use to lighten the pull of my clutch?      Everything checks out ok (used the dial indicator) about 2 threads showing, acuator is in good shape too (no slop), cable has no sharp & very few bends.        There is a slight drag in the clutch with a little cable slack but still hard to pull and when i take the slack out of the clutch cable there is no darg but the pull is very hard.  Any ideas?

'12 Husaberg TE300
74 Yamaha TY 250
84 Yam IT200
75 Jackpiner w/ 250 eng.
82 KTM GS250II (import)
82 KTM 495 (2)
98 KTM 300mxc
04 KTM 125 SX
00 KTM Duke 2/rd. racer
06 KTM 950 Adv.
08 Suzuki DR70Z

[brian kirby]

Are you using a Magura lever? Fancy modern levers dont have enough throw to completely disengage vintage European clutches. Not much you can do to make the pull easier that you have not already done. Heavy pull should not be a big deal though, you only use the clutch to get moving right?

Brian

[JCHubbard]

Mike,


Re: Hard Clutch Pull

I had the same problem you are currently experiencing -- however it was on a 79 Maico 450 GS, which is equipped with a Magura. If I raced MX only, then I wouldn't change my clutch/perch lever, but I'm a woods racer and the clutch pull with the Magura setup (even with a brand new Teflon coated and carefully routed clutch cable), was absolutely destroying my left hand during cross country races.
     So last week I purchased a new Barnett clutch pack kit, new clutch spring, and a new clutch lever for the said Maico.  But before I removed the clutch cover to undertake the job, I installed the new aftermarket clutch lever/perch that I bought on Ebay. I didn't anything would change after I installed it the clutch/perch lever this past Sunday, but man was I surprisingly wrong! The pull with this lever is probably 70-80 percent better compared to the Magura lever.  I've tried other aftermarket levers on the same Maico, but there was no improvement.  However, this new set up was the best yet -- it made the pull WAY lighter.  I'm actually going to buy 1 or 2 more to keep in stock, just in case I can't find these anymore.

http://www.ebay.com/itm/Maico-Husky-Bultaco-Clutch-Compression-Release-Levers-/170461396313?hash=item27b04a7d59&item=170461396313&pt=Motorcycles_Parts_Accessories&vxp=mtr

In the Fall, after the season is over, I'm going to install the new clutch kit, wheelsmith clutch spring, and freshen up the topend.  And I am really forward to seeing how much nicer this is going to be once the clutch basket is polished and the new items are installed.  But for now, I'm satisfied with the new clutch/perch set up.  

Good luck!

John

[brian kirby]

John, the clutch doesnt drag? I've tried a few of those EZ pull levers and none of them had enough throw to work right, but I have not tried that one. If that spring from Barnett is the single coil spring, it wont work for a 450, you have to use the belleville washer stack to get enough spring tension for anything bigger than a 250.

Brian

[tomale]

Mike, Behind the clutch, there is push rod, a steel ball and then another push rod, If these get rusty or crusty. then the clutch pull will be very hard indeed. Maybe some of the other guys can talk about this more but I think that you have to take the clutch  a part and remove the clutch actuator. then remove those rods and ball, flush everything out, some light lube on the rods and reassemble.

Thom Green,Still crazy after all these years!
76' 250 MC5 (orginal owner)
74'250 hare scrambler (project)
74' 1/2 440 maico
78' 440 maico
72' cr125 Husky (project)
93' RMx 250 suzuki

[JCHubbard]

quote:Originally posted by brian kirby

John, the clutch doesnt drag? I've tried a few of those EZ pull levers and none of them had enough throw to work right, but I have not tried that one. If that spring from Barnett is the single coil spring, it wont work for a 450, you have to use the belleville washer stack to get enough spring tension for anything bigger than a 250.

Brian

Brian, the last clutch/perch combo I used on the Maico 450 was a MSR Raptor set up...It worked only slightly better than the Magura, but no where as good as the current set up I have. No slipping or dragging noted on the MSR or the new one installed on Sunday. You've probably experienced this -- almost every Maico I've ever owned since the late 70's needs to be properly warmed up before you can truly assess their clutch operation -- as they all have a little cold engine creep until they are warmed up.  My little trick with installing aftermarket clutch/perch lever (at least on a Maico!) is to shim your cable housing right where the cable attaches to clutch case. I've also used an ASV clutch/perch lever set up with extended clutch actuator on the case my previous 84 Maico 250, and it was it was very good too, but I didn't feel like paying $100.00+ for a new clutch perch set up this time.

However, Brian the best thing I ever used to improve the Maico's clutch action was to install a Kevlar clutch kit that I bought from Bill Eyler and ran on my 79 Maico 250 GS..Even with a Magura perch, the Maico 250's clutch pull feels as good as the hydraulic clutch set up on my 2008 KTM 250 XC.  

The clutch spring I'm using is a Wheelsmith Replica copy from Bear Sports. I'll give it go...Worst case scenario, is that I'll have to stick with the Bellville washer stack...I can definitely live with this set up now...

John

[Mike Hufnagel]

Yep, have the Magura lever. Tried an e-z pull before too, didn't like it.   I want to say that the push rods & bearing are okay.( I will recheck that when I pull the clutch apart this week).      I am a woods only rider & the clutch on it now is not acceptable to me. It's like one of those  hand grip excercisers but only worse!  I am questioning the springs because I don't know who had built it before I had purchsed it.  I know that its not going to have anywhere near the pull of a modern clutch, but it is bad.

'12 Husaberg TE300
74 Yamaha TY 250
84 Yam IT200
75 Jackpiner w/ 250 eng.
82 KTM GS250II (import)
82 KTM 495 (2)
98 KTM 300mxc
04 KTM 125 SX
00 KTM Duke 2/rd. racer
06 KTM 950 Adv.
08 Suzuki DR70Z

[Mike Hufnagel]

PS.   Do they even make clutch paltes for Pentons?

'12 Husaberg TE300
74 Yamaha TY 250
84 Yam IT200
75 Jackpiner w/ 250 eng.
82 KTM GS250II (import)
82 KTM 495 (2)
98 KTM 300mxc
04 KTM 125 SX
00 KTM Duke 2/rd. racer
06 KTM 950 Adv.
08 Suzuki DR70Z

[JCHubbard]

quote:Originally posted by Mike Hufnagel

PS.   Do they even make clutch paltes for Pentons?

Mike,

I'm not sure...Hopefully, a POG member will be able to have the answer for you.

BTW, my clutch felt like hand grip exerciser too.  I've seen some guys modify (extend) the clutch arms on CZs and some Maicos, but I'm not sure what mods are applicable to a Penton or not.

John

 

'12 Husaberg TE300
74 Yamaha TY 250
84 Yam IT200
75 Jackpiner w/ 250 eng.
82 KTM GS250II (import)
82 KTM 495 (2)
98 KTM 300mxc
04 KTM 125 SX
00 KTM Duke 2/rd. racer
06 KTM 950 Adv.
08 Suzuki DR70Z