clutch rod - 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 8 Old 08-13-2015, 03:37 PM Thread Starter
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Join Date: Mar 2015
Location: harrington park nj
Posts: 22
Question clutch rod

I was wondering I have a 98 been having issues with clutch grab when you let lever out and there seems to be a lot of play in cable
I replaced cable and still can't get it engage seamlessly
is that clutch rod suppose to come out when I put new cable it seemed like I could pull it up and out never seen that before
bike has 21k don't think I need new clutch it down shifts good you can feel it pull
I just can't seem to get it right when you let it out
I have had lots of bikes and this is first time ever had this problem
thanks for any info
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post #2 of 8 Old 08-13-2015, 06:32 PM
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If you can pull the rod that the lower end of the clutch cable hooks to up and out, it is not installed properly.

Take the cable loose from it and turn it so the lever on its end is pointed back toward the back axle. Then lower the rod until it is about 1/8 inch from bottoming out and rotate it clockwise until the lever is pointed straight back at the engine. You should feel it catch and resist turning any farther. Make sure you can not lift it up and out. Reconnect the cable and you are good to go.

Last edited by GoMotor; 08-13-2015 at 06:34 PM.
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post #3 of 8 Old 08-14-2015, 04:00 PM Thread Starter
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Question clutch rod

just want to say thank you got it lock and clutch seems much better
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post #4 of 8 Old 09-16-2015, 07:47 PM
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Quote:
Originally Posted by cchuckie51 View Post
just want to say thank you got it lock and clutch seems much better
did your clutch feel like it was never fully disengaged when pulled in?
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post #5 of 8 Old 09-17-2015, 12:13 AM
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Location: Chilliwack, BC, Canada
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Many clutch engagement issues are caused by poorly lubricated cable toggle in the lever and by poorly lubricated handlebar lever pivot bolt. The binding toggle also is a big cause for broken clutch cables because the binding prevents the toggle from rotating and this bends the cable where it goes into the toggle.
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post #6 of 8 Old 09-17-2015, 06:09 AM Thread Starter
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Lightbulb clutch

my clutch would disengage but when you let it out it seems to grab quick there was no ease into it
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post #7 of 8 Old 09-17-2015, 08:13 AM
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Join Date: May 2015
Location: Bergen county, NJ
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Chuck, this monday my new KLR service manual suppose to arrive and in the mean time I'm using electronic version online. Call me if you need anything. I should have more time on weekend this coming months.

Mark
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post #8 of 8 Old 12-14-2016, 12:17 AM
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Join Date: Apr 2016
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Quote:
Originally Posted by GoMotor View Post
If you can pull the rod that the lower end of the clutch cable hooks to up and out, it is not installed properly.

Take the cable loose from it and turn it so the lever on its end is pointed back toward the back axle. Then lower the rod until it is about 1/8 inch from bottoming out and rotate it clockwise until the lever is pointed straight back at the engine. You should feel it catch and resist turning any farther. Make sure you can not lift it up and out. Reconnect the cable and you are good to go.
Thanks, I'm installing a new cable and was fighting this rod because it always popped up.

I figured out what I did wrong. I thought the rod should be pushed all the way back and pointed backward. arrrgh.

Last edited by ronenfe; 12-14-2016 at 12:26 AM.
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