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April 11th, 2011, 10:10 AM   #1
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2010 FX450 Clutch problem

I just picked up this bike on saturday. I have been taking it easy for the break in, today I hit the 3 hour mark (yes I changed the oil/filter after one hour and put the recommended motorex 10w - 50 in it) anyway.. So according to the manual I kept it lower than 50% throttle in the first three hours. Today right as i'm getting 3hours on it I just popped through 1-4th gear at about 40% throttle and all of the sudden as i'm shifting 3-4 gear probably when I noticed something was weird my clutch won't pull in as I slowed down I popped into 2nd gear and rode it home. I cannot pull the clutch in without feeling like i'm going to break something.

The short version: My clutch lever wont pull in it feels like it is pressurized or something. I am new to hydraulic clutches so I don't know if i'll break something if I pull it hard to see if it will finally engage again..

Please help if you can, Thanks - Matt
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April 11th, 2011, 02:52 PM   #2
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Re: 2010 FX450 Clutch problem

Well guys i'm back at my computer again.. I have checked the lines running from the clutch and they are not kinked or anything. When I try and pull the clutch it feels like a brake lever (obviously because it has hydraulic pressure) anyhow i'm stuck right now the bike still has 30 day warranty but my dealer isn't open mondays. I would open it up and check it out but since i'm under warranty i'm going to wait. I hope it is a simple and easy fix but I can't imagine what it could be...

What do you guys think? Should I open up the fluid resevoir and see if it will depressurize? I'm leaning towards waiting to talk to my dealer, really wishing I could be out riding it is a nice day..

Thanks for any advice - Matt
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April 13th, 2011, 10:33 AM   #3
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Re: 2010 FX450 Clutch problem

Apparently it was a "manufacturing defect" a nut inside the clutch had come lose and would'nt allow the clutch slave cylinder to push the rod that activates the clutch. My dealer fixed it within 20 minutes

*whew*

I'm new to this forum but i'm not surprised no one knew of this it is a really weird problem.

This forum is awesome guys/girls thanks for all of the information (aside from none on this clutch thing haha)..
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April 13th, 2011, 07:28 PM   #4
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I Ride: '10 Husaberg FE 450, '01 Honda CR250
Re: 2010 FX450 Clutch problem

Good thing you did not force it. Glad to hear you got your problem sorted.

This forum and the Husaberg Forum on KTMTalk are fantastic resources. These new bikes seem to be inherently reliable but they do have some common bugaboos that are well discussed in the forums.

These are in summary:

1) The stock fuel filter may not stop all the debris, resulting in injector problems. Addressable by replacing the stock quick connect under the tank with an inline canister filter.

Newer bikes can get a white film on the fuel pump filter screen. Something to do with mold release or something in the tank when new from the factory. Mine did not have it, but some really get plugged up.

2) The exhaust pipe gets hot and can cause the gas to boil in the tank. Addressable by lining the bottom of the tank with heat reflective tape and wrapping the rear section (ahead of the silencer) with DEI header wrap, available at Autozone type stores. Ceramic coating is a good idea too that I want to pursue.

The stock exhaust has 2 discs in the end held on by a star nut. These are purposely restrictive. Restriction in the exhaust builds heat. Get rid of them.

3) The gas cap has a gray ball inside to seal it off. It is suggested to get rid of that too, so the tank does not pressurize if the gas gets hot and boils. I also drilled the vent out too while I was at it, as it has a wee tiny hole. Also threw away the 3 pronged thingie in the cap so it twists off easily and normally, without having to push down on the gray vent part.

4) The fuel pump electrical connects inside the gas tank can disconnect, safety wiring these on is a good idea.

5) The rear end like more sag than normal. Set race sag around 120mm (around 4.5") instead of the usual 4" (100 mm). The stock springs are soft if you weigh more than 180 or so.

Sounds like i am bitching - I am not - these are amazing bikes. They are even better with some setup though
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April 13th, 2011, 11:09 PM   #5
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Re: 2010 FX450 Clutch problem

Yeah I have read about some of those problems I still love this bike. The most annoying thing so far has been my tail light breaking the US version hangs lower than the nice and sexy euro tail so the tire took out my tail light..

You think setting my rear suspension up to race settings would probably help my tail issues?
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