clutch problem - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 2 Old 08-18-2007, 09:37 PM Thread Starter
Join Date: Jul 2007
Posts: 16
clutch problem

So i replaced my clutch on my 99 KLR 650. Put it all back together, h20 pump back on, cover on oil filter in, hooked the cable back up...before filling with oil, i thought Id pull the clutch lever in adjust it etc....
well i pulled it in, the lever went to the bar and stayed there. No return...

what pulls the lever back away from the bar?
I did not see any spring etc on the clutch release lever. I inserted it into the top of the clutch cover, rotated it about 180 degrees to slide all the way down, so i think it is installed properly. Should a person be able to push on the clutch release lever with his thumb and get a springy feeling? Mine just feels like it hits a wall. Spins and then stops. no building resistance.

I removed the cover again, and the shaft or in the middle of the clutch hub moves in/out very slightly. I am not sure how it works and am wondering if there should be some resistance there.

I am pretty sure i put it back together properly. Not much to do wrong is there? Is there a special way of inserting the clutch release lever that will catch the rod properly?

I am way confused here. Also looks like my cable is F'ed as well. THere is no play in it when I pull one end of it. Maybe thats what f'ed the clutch in the first place. No sliding in the housing going on....

Help please!!!
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post #2 of 2 Old 08-19-2007, 12:41 AM
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Daddyjoe's Avatar
Join Date: Sep 2006
Location: Riding around the USofA
Posts: 1,429
There is a certin way to reinstall the clutch release lever. Clymers says,
"turn the clutch release lever so it points back, then install the cover. When the cover is installed turn the release lever forward to engage it with the clutch lifter."
The wire cable should move freely inside the plastic housing.
I would invest in a Clymer Manual if you plan on doing much work on the bike.

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