New member, Southampton area

[drillam]

Hiya
Just got a MK1 for cheap off roading as I killed my old KLX650 and I'm getting too old to pick up heavy 4 strokes any more :-)

http://i14.photobucket.com/albums/a340/ ... C01552.jpg
http://i14.photobucket.com/albums/a340/ ... C01565.jpg
http://i14.photobucket.com/albums/a340/ ... C01570.jpg
http://i14.photobucket.com/albums/a340/ ... C01574.jpg

I've only ridden it round the garden so far as I had to do a very small amount of work on it, like replace the headstock bearings and front tyre, fit my homemade risers I made for the KLX, and generally give it a going over.

So I have a wee list of questions I'm hoping you can help me with.

I've found that the clutch is like an "on off" switch which can't be too good in the mud an dirt. Is this normal on these bikes? or is something amis in the adjustment?
I'm making a new clutch cable anyway as it's the only thing that needed extending with the risers.
Is there a mod? or a simple adjustment I can do to make the clutch take up more progressive?
I was thinking of reprofiling the clutch lever pivot point but wondered if anyone here has gone through that process or found a simpler way.

As you've probably guessed I have no workshop manual for it yet, it's a 1989 model, MK1 I beleive.
Is there a free down load type manual anywhere?
Where's the best place for spares?
I want to put fork gaiters on and no doubt there will be other wee mods'n'sods to do after I've ridden it off road for the first time.

Sorry for all the questions on my first post.
Thanks in advance for any answers.
cheers
Millard

[fallenmikethebike]

Hi Drillam , welcome to the site.
A fierce clutch on a bike as old as your MK1 will more than likely be caused by wear on the tines of the clutch basket,
where the clutch plates chatter against the tines , you end up with grooves, that give the fierce action you describe.
A light dressing with a file gives a temporary fix, but a new basket is the real answer.
You can source a brief workshop guide , and any spares from Leisure Trail
Tel 0115--973---2466
Regards Mike

[knackeredMk1]

Welcome. Nice bike that doesn't seem to have seen much off road action . Clutch as per FMtB. See near bottom of viewtopic.php?f=14&t=3484&start=0

Seat has been cut down a lot - you might want to take it back to original as it will make moving about the saddle much easier

Those head bearings are probably the originals as everyone changes to tapered rollers when they need to be replaced .

[drillam]

Thanks for your replies guys.
Well I'm used to dressing clutch baskets on Norton singles, didn't expect to have to do it on a "modern" bike :-)
£340 for a new basket is over half of what I paid for the bike - £580 including the bearings and new front tyre, so I'll dress it until a good used one comes along. At least it'll be easier than the steel Norton ones.

Seat is far too low for me with 36" inside legs, so it was a question I was going to ask, about getting a replacement. However if the original has simply been cut down - can I get an original foam seat mould and cover? or is it a DIY job?
Alternatively, is that CR500 seat that you fitted easy to mod KnackeredMk1 ?
I see there's a few on fleabay at the moment.

More to come I'm sure.
Thanks so far, much appreciated.
Millard

[MarkF12]

Hello and welcome ,I like the bar risers good idea.

[knackeredMk1]

CR500 seat mod - You have to shave side panels, make new lugs that engage the frame at the front and new brakets for the back of the seat. You also have to modify the seat to engage with the tank and shave some of the sides of the seat base. The seat is shorter so passengers (if you were thinking of taking them) are much closer

Not difficult just fiddley . It's the last CR500 version that you need. I think that they changed in 1992, but I'm not at all sure.

[drillam]

[quote="MarkF12"]Hello and welcome ,I like the bar risers good idea.[/quote]

Thanks Mark, I need them, I'm 6'6"

[drillam]

[quote="knackeredMk1"]CR500 seat mod - You have to shave side panels, make new lugs that engage the frame at the front and new brakets for the back of the seat. You also have to modify the seat to engage with the tank and shave some of the sides of the seat base. The seat is shorter so passengers (if you were thinking of taking them) are much closer :!:

Not difficult just fiddley ;) . It's the last CR500 version that you need. I think that they changed in 1992, but I'm not at all sure.[/quote]


Thanks again Knackered, if I can't find a new foam base I'll give it a go.

[knackeredMk1]

You won't find a new foam base as Honda don't sell them and no aftermarket company do them. Honda only sell the whole seat and I dare not think how much that would cost if they have any left. You could try LT but they didn't find any when I was looking. (I've looked up the part No. for Mk1 seat on Lings and there are no matches).

Usual source is eBay or on here but you have to be careful as the seat cover can cover a multitude of sins. Mk1 & Mk2 seats are the same.

[drillam]

Ok thanks for that.
I dressed the clutch tines today, as you both suggested - it needed it.
Did it as per Knackerd's thread, file first then 1500 grade wet'n'dry. I was surprised how soft that ally is.
I'm just waiting for a clutch cover gasket from LT and some fork gaiters, should be here tomorrow so should have it out on the road in the next few days and if all goes well I'll nip over to Salisbury Plain sometime later in the week or maybe the weekend and try it off road. After that I'll decide what to do about the seat height - I think I can feel a CR500 seat coming on though.
One thing that I noticed when taking off the clutch cover - I'm not too used to 2 strokes so I removed the oil pump thinking that it just might be the cause of the stubborn to remove clutch cover (it wasn't), anyway in the bottom of the oil pump casing there was a fair bit of swarf, looked like ally perhaps but could be steel, I'll have a closer look tomorrow as I've locked the shed for the night. It was laying under the oil pump itself, at the bottm of the housing, enough to be noticeable.
Any ideas what might cause that? Can't really thing where that could have come from.
I think me wallet's trembling.
FYI
The speedo shows 24,000 Klms, but who knows on a machine this age?
Bike feels nice and tight, starts first kick hot or cold and doesn't look too abused, just needed a wee bit of updating on the maintenance and consumables, most of which the previous owner did before selling to me. But he didn't use it.
Gut feeling is that it's mechanically good. Droped the gearbox oil and it looked OK, no swarf or gold coloured bearing material or anything like that.
Cheers
Millard