2002 xr 80 clutch pull

[KLXED]

My son has a 2002 xr 80 with very hard clutch pull.
Has any one put a hydraulic clutch on this bike ?
or any other advise on this problem.

 

[whyzee]

I modified my sons xr clutch lever. Take a look. The job took 30 minutes, drill, 1/8 bit, 5/16 bit (i think) let me know if You need me to explain further. Same principle as the MSR Raptor.
picture 1

picture 2

Good luck

 

[KLXED]

Thanks for the help I'm going to try it soon.
let you know how it works.

 

[whyzee]

glad to help!

 

[KLXED]

Dave,
I relocated clutch cable as you showed in pic's
it worked great !!!. My son says thanks.

 

[whyzee]

glad to have helped!

 

[Patman]

Hard to imagine why a bike geared to the little ones has such a solid pull and a loooong reach. I did the same mod a month ago when we got our '02 and it made a huge improvement. I'm still considering ordering up some KTM 50 lever assemblies since they are closer to the bars. Worst case would be ordering up a kit from E-rider which would require a different hose between the slave & master with a shorter length. (why yes I did investigate this in depth) ;)