KTM 790 Adv Clutch Pull Modification

Monday, Sep 16 2019 [1,020 miles]

One of the few things that I’d change on the 790 is the clutch pull. It’s not a heavy pull, but there are only a few millimeters of lever pull between full disengagement and full engagement. That makes it harder to feather the clutch just right for low speed operation. Oh, look. Someone has made something to fix that.

In today's mail

In today’s mail

In today’s mail
1 finger clutch

1 finger clutch

1 finger clutch

This bit of kit increased the length of the lever arm attached where the cable attaches to the clutch mechanism. A longer lever translates to both a longer engagement and an easier pull. Win-win.

Stock setup

Stock setup

Stock setup
removed

removed

removed

This shows the stock setup. The hardware that attaches the stock cable bracket is re-used to attach the replacement bracket. I also re-used the pinch bolt because I want to stick with the stock TORX screw instead of using the socket head cap screw that came with the kit.

Hardest part of the job

Hardest part of the job

Hardest part of the job
New lever installed

New lever installed

New lever installed

The hardest part of the install was re-inserting the dust boot on the end of the clutch cable after removing it to snake the cable out of the stock bracket. A little bit of rubber safe silicone grease helped. It was still hard.

The new lever is installed and all feels well. I haven’t taken the bike on a test ride yet. Perhaps tomorrow.

Tuesday, Sep 17 2019 [1,029 miles]

I loaded my camping gear on the bike for a Thursday-Sunday trip. Once loaded I took a short test ride to check out both the clutch lever install and how the bike feels with the gear loaded. Clutch engagement range is perfect for my taste, no more on/off action. The lever pull is almost too easy; I’m sure I’ll get used to it.

The camping gear didn’t move around. I’m good to go.

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