FAQ

KX450 CLUTCH LEVER ADJUSTMENT

CLUTCH MOVED AWAY FROM GRIP,SWITCHES MOVED TOWARD GRIP

CLUTCH FULLY DISENGAGED WITH LEVER OFF OF OUTER FINGERS

STANDARD LEVER

  • INSTALL LEVER, LUBRICATE EVERYTHING WITH GREASE
  • ADJUST HANDLEBAR ITEMS FOR MAXIMUM ROOM
  • ADJUST LEVER POSITION SO CLUTCH IS COMPLETELY DISENGAGED WITH THE LEVER A BIT OFF OF THE OUTER FINGERS

INSERT LEVER

  • SELECT DESIRED INSERT, WE RECOMMEND 16MM
  • INSTALL LEVER, LUBRICATE EVERYTHING WITH GREASE
  • ADJUST LEVER PLAY, ZERO TO .1MM OF PLAY AT STOP
  • ADJUST HANDLEBAR ITEMS FOR MAXIMUM ROOM
  • ADJUST LEVER POSITION SO CLUTCH IS COMPLETELY DISENGAGED WITH THE LEVER A BIT OFF OF THE OUTER FINGERS

*REGARDLESS OF RATIO OR BAR POSITIONING, THE CLUTCH MUST BE FULLY DISENGAGED WITH THE LEVER SLIGHTLY OFF THE OUTER FINGERS. OTHERWISE CLUTCH WILL DRAG, HEAT UP AND WEAR OUT BEFORE IT SHOULD. IF THE LEVER PULL IS TOO HARD, TRAIN MORE.

INJURY OR DEATH MAY OCCUR

IT IS EXTREMELY IMPORTANT TO ADJUST THE FREEPLAY FOR EVERY INSERT INSTALLED.

IF YOU OVER PRELOAD THE PUSHROD, THE INTERNAL

PISTON MAY NOT RETURN ENOUGH TO LET THE BRAKE FLUID RETURN TO THE MASTER CYLINDER RESERVIOR.

THIS CAN CAUSE INJURY OR DEATH!!!

ADJUSTING THE FREEPLAY IS VERY SIMPLE.

  • LOOSEN THE LOCKNUT AND BACK OUT THE SET SCREW
  • INSTALL THE DESIRED INSERT
  • INSTALL THE LEVER IN THE MASTER CYLINDER
  • USE A STRIP OF WRITING PAPER AS A “FEELER GAGE” BETWEEN THE LEVER STOP AND M/CYL. BODY
  • TURN THE ADJUSTER SET SCREW IN UNTIL THERE IS A SLIGHT TENSION ON THE PAPER
  • TIGHTEN THE LOCKNUT
  • ADJUST THE LEVER REACH FOR PERSONAL TASTE
  • CHECK FOR CLEARANCE BETWEEN THE BRAKE LEVER AND THROTTLE HOUSING, ADJUST POSITIONING IF NECESSARY
  • BE CAREFUL WHEN APPLYING THE BRAKES FOR THE FIRST FEW TIMES SINCE THE RESPONSE WILL BE DIFFERENT FROM YOUR PREVIOUS RIDE