Grinding Clutch - 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 7 Old 05-17-2016, 08:45 PM Thread Starter
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Grinding Clutch

2007 KLR 650. Grinds when I pull the clutch lever in. I had recently switched off to the rotella oil after reading on some forums. Didn't happen till after. Clutch lever feels a little loose as well, doesn't snap back after releasing. Any suggestions?
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post #2 of 7 Old 05-17-2016, 08:56 PM
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I am no KLR "expert" but would like to here more about the grind because my first thought is... sounds like a bad cable, starting to come apart inside...

"Things are made out of Stuff"
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(2011 KLR)
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post #3 of 7 Old 05-17-2016, 08:59 PM Thread Starter
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Grinding may not be the right word,I guess the clutch plates sound like they are grinding together in a way.
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post #4 of 7 Old 05-17-2016, 09:41 PM
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Like a hard jerk when you first put it in gear, like the clutch is sticking?
Only on first start-up? Warmed up it is fine?

I run 15-40 Rotella, no problems..

"Things are made out of Stuff"
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"Singularity is a scientific term for - We Just Don't Know"
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post #5 of 7 Old 05-19-2016, 12:11 AM
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Your oil is fine. Many use exactly that. Need more description of the noise.

Dose it sound like gears grinding or like bird wings flapping when you scare up a flock?

Does it happen:
While accelerating/decelerating with out pulling the lever?
while stopped in gear with the lever pulled?
While letting the lever out to engage the clutch?
While going from neutral into first?

How much free play do you have in the lever before the engage/disengage point:
1/2"?
Half the range?
Almost the full range?
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post #6 of 7 Old 05-19-2016, 12:20 AM
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I wonder if it is the release bearing failing? That could make a grinding noise when the lever is pulled.
JJ
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post #7 of 7 Old 05-20-2016, 06:49 AM
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Not enough information as to when and how it occurs. Most bikes which come here have lever pivots which are as dry as popcorn. If they haven't been cleaned and greased and the noise is in the lever, .....I'd service them regardless.

Pay attention to the toggle which connects the clutch inner cable to the lever. It needs to be clean and greased also. I'm convinced that is the main cause of cables breaking.
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