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September 21st, 2006, 04:58 PM   #1
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I Ride: 99 ktm 200exc, 96 CR265, 77 xs650 bobber, 2000 honda superhawk
96 fc 501 clutch drag problem

noticed i have significant clutch drag even with all the adjusters at their limits. this bike is brand new to me as of yesterday. i have had several bikes and done lots of clutches. it sounds like me that the basket may be grooved. can these be filed down a bit like the jap bikes? other ideas gladly anticipated! i love this bike so far.
is there any clutch adjustment other than the in line ones and at the handle?
thanks in advance!
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September 21st, 2006, 08:16 PM   #2
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Re: 96 fc 501 clutch drag problem

Originally Posted by Bucklee
noticed i have significant clutch drag even with all the adjusters at their limits. this bike is brand new to me as of yesterday. i have had several bikes and done lots of clutches. it sounds like me that the basket may be grooved. can these be filed down a bit like the jap bikes? other ideas gladly anticipated! i love this bike so far.
is there any clutch adjustment other than the in line ones and at the handle?
thanks in advance!
I think you will have to inspect the basket to be on the safe side. I own a 96 FE 501 and when the clutch really drags what I did was remove the clutch cable on the handle bar side or you might want to remove the whole cable and oil the inner cable, work the cable in and out while doing so. Might be easier just to soak the cable in oil for a while. When the oil runs out the lower end then you have enough. Another point is where the cable adjuster is at the bottom. Be sure to lube it as well (likes to bind and will break). The stock cable had caps you could open and add lube but the above is the best way a little messy but it works.
Hope this helps.
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September 21st, 2006, 08:51 PM   #3
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cable is perfect and is putting good throw on the arm with no drag. unfortunately no easy fix on this one.
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September 21st, 2006, 09:02 PM   #4
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Make sure the lever assembly is OEM Magura unit. Is hard to reach with the long distance to the lever and the pull is stiff due to the leverage ratio, but it moves the cable a lot which in turn moves the clutch arm a lot helping with the drag problem. Removing the aftermarket clutch lever/perch assembly and installing the Magura fixed my 96. In Dirt Bikes test of the 97 models they stated that the 97 pressure plate was beefed up to reduce flex which helped the disengagement. I never tried a 97 pressure plate, so can't verify that it will fit, but I watched the pressure plate move on my 96 and it flexed a lot. Maybe some other member can verify that the 97 pressure plate is in fact updated and will fit.
dan
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September 21st, 2006, 10:30 PM   #5
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I Ride: 99 ktm 200exc, 96 CR265, 77 xs650 bobber, 2000 honda superhawk
my lever looks like stock as as far as i know... but it looks like a domino style lever. there is so much adjustment on it that i know for a fact that it should disengage enough for me to get it into gear without killing it at least. i had a similar problem when i used regular oil (car kind) in a kx 125 when i was about seventeen, it may be possible that the guy i bought it from did this too?
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September 22nd, 2006, 06:40 AM   #6
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Maybe if it was real heavy car oil. Used to see Domino levers on my early 90's Huskys. Guess Husaberg could have used some. Not sure of the leverage ratio on a domino.
dan
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September 22nd, 2006, 06:06 PM   #7
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looks like it was the oil. looks like it hadn't been changed for a long time. i am planning on doing a triple flush now. hopefully itll soak into those plates and make the drag/slip better.
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