Hydraulic Clutch for LC4 Adventure

Discussion in 'Thumpers' started by Scotty, Dec 23, 2002.

  1. Scotty

    Scotty Adventurer X

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    Hey folks,
    Since your still here I decided not to start a new thread!

    Arch and cat0020: I ordered the Magura Hydraulic kit for my 02 Adv. and had a seriously HARD time mounting it because of the signal control housing so before you order the Magura kit call your local Katoom shop (or email me at mine @ scott@dfwktm.com) and try to get a complete hydraulic clutch from the 03 Adv. The clamp for the NEW clutch is a little longer and will alow the lever adjuster to clear the control housing!

    KTim: The new seat on the 03 Adventure is WAAAAAY BETTER!

    Here is a link to the pics of my 03 Adventure and Akropovic exhuast:

    http://www.pbase.com/bakerfarm/katoomst of all here are the pics[/URL]

    Have a good one,
    #1
  2. Arch

    Arch Incurable Gearhead

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    Thanks for the heads up, bro. Seems if it's the same as the '03 625 SXC's factory hydraulic clutch setup (Magura as well), it won't work on an '02 or earlier LC4. Or at least it won't work at the engine 'cause the newer ones have an internal mechanism there, while the kit has a little slave cylinder that needs to be installed in the cable stop that '02s & earlier have.

    Or ... Am I missing something here, Scotty? Maybe you're saying that just the controls can be mixed & matched? In other words, the factory '03 controls along with the kit to convert earlier ones from there on down to the gearbox? Thanks for the time...

    :beer

    Arch
    #2
  3. boyscout

    boyscout sittin' down

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    I did it for you. :):

    -BS
    #3
  4. Cat0020

    Cat0020 El cheapo

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    I have a Magura hydraulic clutch kit in the garage, but still have yet to really stare at the bike to figure out how the thing goes onto the bike. I think the biggest challenge should be routing the sealed clutch lever or the moving cylinder underneath the fairing.
    If I get sometime to myself instead of entertaining my family, I could probably get it working before New Year.
    #4
  5. Arch

    Arch Incurable Gearhead

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    Just pop off the tank, Cat. First remove the seat (one 8mm bolt secures it from below), then the two 8mm fasteners on each side that secure the fairing to the tank, then the two fuel lines (make sure both taps are closed first). The tank will come right off with a tug towards the rear and obviously this is best done when it's empty.

    BTW, you'll be surprised at how tiny the thing looks with that giant tank removed!

    Anyway, looking forward to hearing about your install.

    You guys have a Merry Christmas, we're all loaded up for a little holiday vacation...

    :): Arch

    Attached Files:

    #5
  6. boyscout

    boyscout sittin' down

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    Don't forget to disconnect the wire to the fuel level sensor.

    Nice setup you got there in the truck Arch.

    -BS
    #6
  7. John Macdonald

    John Macdonald Long timer

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    don't forget the marshmallows for the campfire-
    #7
  8. Arch

    Arch Incurable Gearhead

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    Whoops! Yep, mine's an '01 so it doesn't have any wires to undo and I fergetted that the scoot in question is an '02. Hope nothing bad came of it!

    As for the truck's setup, well, I'm often accused of being anal about how things are arranged & secured ... so thanks for noticing.

    :rofl

    Arch

    PS, the ride was a complete hoot, as usual. Will post some pics in Ride Reports soon. In the meantime...

    Attached Files:

    #8
  9. Tim

    Tim Long timer

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    Arch,

    What's the orange bit on your tank - has the paint worn off or is it a sticker?
    I only ask because I have just got my new Adventure and will try to protect the paint if it is paint loss on yours.

    Tim
    #9
  10. Cat0020

    Cat0020 El cheapo

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    Are you serious?
    KTM is meant to be ridden, not to look pretty.
    The more scratches the more character, I don't even clean off the mud that's baked onto the muffler, that works as a protective layer from rocks and sticks that fly up from behind.





    :rofl :rofl
    #10
  11. Arch

    Arch Incurable Gearhead

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    It's just a little KTM logo, Tim. Only area worth trying to protect are the tank & fairing sides 'cause even the most innocent of sandy lowsides lays waste to the paint. No big deal given the bike's mission in life, but out where I ride this thing on occasion, a fast get-off could conceivably bore right through the plastic at the tanks lower edge. That'd suck in the worst possible way out there. See this thread for related gab, but basically I had the area covered with a rubberized coating like what's used on truck beds and it's thicker at the areas needing the most protection. One of these days I'll do a new thread about the stuff and include some better pics. So far it's held up just fine to passing thorny bushes that used to rip gouges into the plastic.

    :beer

    Arch
    #11
  12. Arch

    Arch Incurable Gearhead

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    Bumping this back to the top. Scotty, can ya add anything here? Thanks...

    Arch
    #12
  13. Scotty

    Scotty Adventurer X

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    HEY Arch,

    Well man, the controls (switch housing) on the 02 and 03 Adventures are the same! The difference is the clutch perch!

    So, I think what you would need would be the Magura Hyd. clutch mod with a stock perch from an 03 Adv.R.......Which could get pricey! Or you could modify or change your controls to the Euro switch (which is an extensive mod in itself)!
    Anyway Bro, hope this helps! Its EARLY:huh !

    I got the Akropovic Titan exhuast put on and after monkey'in with the carb for a week I finally got my 03 back together! At least enough for a quick ride around the 14 acre field next to our shop and WOW:jump its a totally different bike!!! I will try to post some pics this afternoon!
    :beer
    Scotty
    #13
  14. witzgall

    witzgall Goin' South

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    I installed the Hydraulic Clutch on my 01 adventure. To make it fit, you need to take a dremel tool to the switch gear. It really is not a big deal, just take your time and do a little at a time. There really is alot of plastic that can be removed without compromising the integrity of the unit. The Dremel tip I used was a small grinding bullet.
    #14
  15. Arch

    Arch Incurable Gearhead

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    Thanks, witzgall. So basically if one just tells their part guy to order a Magura hydraulic clutch kit for a KTM LC4, that'll result in eveything needed? (I always welcome an opportunity to whip out the Dremel!) If so, I'm gonna order up the stuff on Tuesday.

    And Scotty, be sure and fire up a new thread on that Akropovic zorst. Love the look! I'm seceretly hoping against hope that it's no louder than KTM's SXC muffler and s-pipe, 'cause I don't want the bike to be loud, but would love to have those sexy pipes...

    :thumb

    Arch
    #15
  16. Cat0020

    Cat0020 El cheapo

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    Well, it took me approx. 4 hours in the 12 degree cold..
    I had to stop working quite often just to get feelings back into my fingers..

    Here are some pictures...
    #16
  17. Cat0020

    Cat0020 El cheapo

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    The Magura kit seems to require 15-20% less force to actuate the clutch.. action is smooth and modulation seems to be better than cable.

    My kit seems to have some air in the system, when the clutch lever is actuating, the slave cylinder makes a hissing sound..

    After riding aroung in the neighborhood for 20 minutes, that was all I could stand in the 12 degree cold; I intentionally stayed mostly in 1st and 2nd gear, and start/stop alot.. the hydraulic cltch seems to be a success. Anyone tired of replacing cable and want a easy challenge to their mechanical skill.. I would recommend it.

    Now if only the weather can get warmer.
    #17
  18. Cat0020

    Cat0020 El cheapo

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    Here's another shot of the naked KTM Rallye..

    It is a great confidence boost, after removing the huge 7 gallon tank.. everything seems possible..
    #18
  19. Cat0020

    Cat0020 El cheapo

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    In retrospect, I think I could have done things faster if it was just a few degrees above freezing..
    #19
  20. Cat0020

    Cat0020 El cheapo

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    Yes, that is snow in the background of teh last two pictures.
    Do I qualify as a hardman now?
    #20