TE clutch pushrod

I've had modest difficulty locating neutral for awhile and pulled the pushrod today. The lower and 10 O'clock position slave bolts were black anodized with SS heads, the 2 O'clock position bolt was SS throughout. Disassembly was straightforward. The pushrod was dimpled .005 ~ .010" on the clutch side and .015 ~ .020" on the slave side.

George at Uptite previously posted a 7.212" spec. I interpolated with my 6" verniers and got an average reading of 7.262" without factoring the dimples.

Removing the slave circlip as Dave Hopkins suggested would make the clutch self adjusting. I superglued a .030" Evoluzione SS shim onto the slave clutch side. We'll see how she does at the Hancock AMA enduro this weekend.

Ive played around with that rod. Just curious, what is your issue? Meaning what has been the problem with the clutch and on what kind of bike?

I did find wear on my rod end, but not much, and that was after two baja race seasons.

<G> Agree! </G>
The pushrod extends ~.100" outside the case. The shim was superglued on the slave side merely for locating the center-line during reassembly.
The slave's internal bore will capture it thereafter.

Clutch pack > Pushrod > .030" shim > Slave clutch


Mike Kay:
Ive played around with that rod. Just curious, what is your issue? Meaning what has been the problem with the clutch and on what kind of bike?

I did find wear on my rod end, but not much, and that was after two baja race seasons.


Husky TE pushrods are aluminium. KTM issued a TSB upgrading 950 pushrods to steel after experiencing problems with clutch engagement. Neutral is somewhat difficult to locate at a standstill, the clutch performs flawlessly otherwise. The bike is an 07 TE510 with 7K miles.

I'll put a few miles on the bike here this morning and again in Hancock this afternoon. If necessary the shim can be removed in minutes.

Update:

The shim worked, neutral is easy to find again.

Any pictures of what you did? My tc250 is hard to find nuetral, and if you are in nuetral and drop it into gear it will stall sometimes, i know the clutch isnt fully disengaging. Im new to hydraulic clutches too...

The Evoluzione shim is merely a #4 SS washer. I interpolated the two pushrod dimple depths and added the shim on the slave side.
Everything is pretty intuitive after taking a few moments to pull the slave and pushrod. Sorry, no pix ...