MR. KNOW IT ALL MR. KNOW IT ALL
OLDER AND WEAKER
Dear Mr. Know-It-All,
I am the proud owner of a new KTM
500EXC, and it’s my first bike in 20
years. I like to ride it to work, but being
a little older, I don’t have the strength
of a young kid anymore. Constantly
pulling the clutch in while driving
through town is wearing my hand out.
Is there any way to make the clutch
pull a bit easier that isn’t too complex?
Thank you in advance for your time.
The Colorado Kid
Via the Internet
Good night, are you a man or a
reasonable facsimile of a genderless
worm with the might and drive of
slime? Start banging out some push-ups. Go dig a hole. Put your bike on a
stand 30 times, but don’t snivel about
a state-of-the-art hydraulic clutch
system when most of us cut our
teeth on Maicos or CZs that had the
clutch pull of a garage-door spring.
Fortunately, my sissy-handed friend,
KTM has fit all of the new machines
with an incredibly easy-to-adjust sys-
tem. Just remove the clutch cover and
you’ll find the diaphragm spring (not
coil spring) that is unique to the EXCs,
XC-F and XCF-Ws. You’ll notice vari-
ous lines above the holes on the plate
that secures the spring. They are listed
as 1, 11 and 111. If you put the bolts
in the holes that align with the single
mark, your clutch pull will be lightest
and accordingly have the lowest ten-
sion on the clutch discs. The three
marks are the toughest pull with the
most pressure on the clutch discs,
and the two marks are where it comes
stock. So, just remove the bolts, turn
the plate to where it all bolts back
together, and go ride.
MONEY IS NO ISSUE
Dear Mr. Know-It-All,
I have completely rebuilt YZ250.
Money is not an issue, I have few
other vices, and I am not a young
rider who just happens to run a large
company. Save your comments like,
“Just buy a new KTM,” etc. I already
have a few of those. I too live in the
communist state of California, and
I needed a green sticker to be able
to practice at a local riding area that
is controlled by the state. No, I’m
not a two-stroke radical; I just have
more fun riding a smoker. I’ve really
been enjoying riding the YZ, and I’m
surprised how good it really is for
a 2002! The only thing I believe it
needs to be close to a modern bike
is a suspension upgrade. Question:
Will the SSS fork, shock and linkage
from a 2007 YZ250 or newer fit and
work correctly? It appears I’ll need
the newer triple clamps also due to a
larger-diameter fork tube—will they fit,
is the stem the same length?
Thanks in advance for sharing your
great wisdom with me, a lowly toiler.
Signed, your humble fan and loyal,
long-time Dirt Bike subscriber.
Nice. Clear, concise and direct. I
like it, so I’ll answer your query…with
the help of Jonathan Belding from
Jonathan explains: “For a 2007 front
fork to fit, he will need to have the tri-
ple clamps to fit the 48mm damper. If
he uses 2008 and newer, he will need
front fork triple clamps and also the
front-brake-caliper bracket. The stem
length is the same.
“With the back end, a 2007 to 2014
rear shock will fit. Structurally, the
shock and linkage are close to the
same. The internal setting is what
improved the rear suspension.
“How will they work? Good
question, as we have never done this
mod, though there is no doubt that
the 2007-or-newer stock suspension
setting will be a gigantic improvement
over his 2002 suspension.”
Editor’s note: We have a guest
editor this month handling “Mr.
Know-It-All,” Mr. Dave Simon. Dave’s
background is basically mad science,
though he’s a sonics aficionado, a
fuel-injection guru and has published
books on jet skis and two-stroke technology. Dave has invented medical
devices and exhaust systems, and has
worked in the motorcycle industry for
the last 15 years.