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

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 18 Old 02-14-2016, 08:06 PM Thread Starter
Neutral
 
Join Date: Feb 2016
Posts: 9
Clutch cable issues

Hi everybody, I'm new to the forum. I recently purchased a 2002 KLR 650. I have been going through the bike trying to get it squared away. The clutch pull felt rough so I replaced the cable and now it appears that the clutch is not fully engaging or it is slipping. If I start the bike in neutral and then put it in gear it does fine, although the clutch seems to release at the very end of the hand lever release. However, if I try to start the bike in 1st with the clutch hand lever fully engaged the bike creeps forward. It has about 14000 miles. Thanks in advance.
Seth
Monty73 is offline  
Sponsored Links
Advertisement
 
post #2 of 18 Old 02-14-2016, 08:37 PM
Threadjacker
 
Lockjaw's Avatar
 
Join Date: Jul 2008
Location: Benicia, CA
Posts: 6,750
Quote:
Originally Posted by Monty73 View Post
Hi everybody, I'm new to the forum. I recently purchased a 2002 KLR 650. I have been going through the bike trying to get it squared away. The clutch pull felt rough so I replaced the cable and now it appears that the clutch is not fully engaging or it is slipping. If I start the bike in neutral and then put it in gear it does fine, although the clutch seems to release at the very end of the hand lever release. However, if I try to start the bike in 1st with the clutch hand lever fully engaged the bike creeps forward. It has about 14000 miles. Thanks in advance.
Seth
My brain is tired, so forgive me if I'm underthinking this, but it sounds like you just need to adjust the cable. The disc by the clutch and down by the oil fill. I like about a nickle's worth of play. That's me. So I adjust until a nickel will fit in the wiggle gap at the clutch lever hinge point.




"In a car you're always in a compartment, and because you're used to it you don't realize that through that car window everything you see is just more TV." R. Pirsig

PPMC #1.
Soon, we ride.

AKA JD Mader or you can call me "Dan" just not early for dinner.

Click my handle for a link to my homepage/blog...which has nothing to do with MCs. Free literature and music! Viva La Revolucion!
-------------------
2008 KLR 650
RIP DM - Soon, we ride.
Lockjaw is offline  
post #3 of 18 Old 02-14-2016, 08:42 PM Thread Starter
Neutral
 
Join Date: Feb 2016
Posts: 9
Ok, I'll give that a shot. Thanks!
Monty73 is offline  
 
post #4 of 18 Old 02-14-2016, 08:56 PM
5th Gear
 
Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
Posts: 3,206
Monty73,

I agree with Lockjaw, it sounds like you don't have enough freeplay in the cable. Give it some more slack and you should be fine! Welcome to the forum!
Regards....justJeff

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
justjeff is offline  
post #5 of 18 Old 02-15-2016, 08:44 AM Thread Starter
Neutral
 
Join Date: Feb 2016
Posts: 9
I adjusted the clutch again and still the same result. If I try to start it in gear, it surges forward like the clutch isn't engaged. If I start it in neutral and shift into first, it seems normal. Any other thoughts?
Monty73 is offline  
post #6 of 18 Old 02-15-2016, 09:42 AM
5th Gear
 
Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
Posts: 3,206
Ok Monty73 I think we misunderstood your original post. When the lever is pulled in it DISENGAGES the clutch allowing the clutch to slip with the engine running. When you let the lever out it ENGAGES the clutch. Your issue seems to be the clutch is not disengaging ENOUGH. To correct that you need to REDUCE the freeplay(slack) in the cable adjustment. This will disengage the clutch more when you pull the lever to the grip.
Regards....justjeff

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
justjeff is offline  
post #7 of 18 Old 02-15-2016, 10:40 AM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,471
Monty73,
Lockjaw suggested 'about a nickels worth' of slack. I concur, but I'll comment that should be with the handlebar turn all the way to the Right.
That should translate to about a 'penny's worth' when straight ahead and about a 'dime to spare' when turned hard left.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is offline  
post #8 of 18 Old 02-15-2016, 10:48 AM
5th Gear
 
Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
Posts: 3,206
Alright I'll bite.... Could either pdwestman or Lockjaw post a picture of their method of gauging the cable freeplay? I am having trouble visualizing how this works. If I am confused imagine how Monty73 might be...
JJ

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
justjeff is offline  
post #9 of 18 Old 02-15-2016, 10:57 AM Thread Starter
Neutral
 
Join Date: Feb 2016
Posts: 9
Thanks for the input. I just want to make sure that I understand. I am suppose to adjust the cable so that there is a nickels worth of slack when the disc on the handlebar is turned all the way out towards the center of the handlebar?
Monty73 is offline  
post #10 of 18 Old 02-15-2016, 11:44 AM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,471
Oh come on now JJ, you know that I can't post pics, without help.

I'm sure you all can feel the slack change 'just a smidgen' as we turn the handlebars from port to starboard and back again. As long as there is at least a 'touch of free-play' at all positions, all is ship-shape.

Monty73,
The 3/8th inch diameter adjuster that the cable goes thru is the adjuster.
I think the disc you are referring to is the 'lock-nut'. Turn the disc to the left, to lock against the lever mount.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting

Last edited by pdwestman; 02-15-2016 at 11:49 AM.
pdwestman is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Clutch Cable proper routing from handlebar down onto engine clutch lever. jaimesix How To's & Tech Guides 14 09-21-2015 01:21 PM
Clutch Cable Booty klr4evr KLR & Other Motorcycle Related Discussion 4 03-25-2015 03:54 PM
Replace clutch cable or!? Renimus Bike and Rider Gear 4 05-01-2014 08:55 AM
Adjusting clutch cable? tri650 1987 to 2007 Wrenching & Mods 6 11-03-2013 12:08 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome