Clutch release lever not seating - 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 6 Old 10-26-2008, 02:01 AM Thread Starter
 
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Question Clutch release lever not seating

So it seems I may have given myself the chance to pull the right crank case cover and clean my oil strainer. I was 20 miles deep in the Oconee National Forest today having a great ride. It was about 6 pm and I was heading out of the woods to ride back home to Athens. I was going about 35 mph on gravel and was cresting a hill and decided to drop down a gear on my way down hill. I pull in the clutch lever and.... WTF... it stays in. I slow to a stall and inspect the cable. There is only one thread of metal holding it to the lever. I whip out my phone... no service. I am new to riding and got a little worried seeing as it is deer season and getting dark.

All of a sudden I realize that if I can get it into first and crank the motor while pulling the throttle I can putt to civilization and reassess the situation. With a bit of lurching and wincing I am on my way. An hour later I reach highway 83 just south of Monticello Ga. I call my wife and ask her to call a tow. She rings me back and tells me the only truck around wants a minimum of $55 to take me the six miles into town. I did the only reasonable thing and cranked her up in first and wheelied, literally, on to the highway. I putted along at 25 mph in first to the town, said fu*k it, and kept going towards Madison, a much bigger, about 25 miles north. I had remembered reading about motocross riders shifting without pulling in the clutch lever and I gave it a shot. I WORKED! At this point is was dark on a deer filled road so I road at 45 mph up to a BP at the I20 crossing in Madison. A guy who worked there offered to give me and the bike a ride home at 11 pm when he got off work. Unfortunately his tailgate was stuck so I'll have to go down and get the bike tomorrow but it is safe where it is. This brings me to my current problem. While waiting for my new friend to get off work, I went ahead and pulled the busted cable off. While I was doing this I lifted up the clutch release lever. I got it to sit back in with a twist but it seems to be sitting too high. It wont rotate past the cable boot but it does seem to rotate out a bit far. Do I have to pull the cover to get it to sit right?

Here are 2 pics of how it is set in, one with it as far away from the boot as it turns and one right on the boot where is seems to raise up:



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post #2 of 6 Old 10-26-2008, 09:45 AM
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No experience with the clutch release lever, so I can't addresss that.

Shifting without clutching is not difficult. Just anticipate the rpm the next gear (up or down) would be at for the current mph and then shift. In other words, add rpm on a downshift and reduce on an upshift. A brisk, hard shift is better than a slow tentative one. This can obviously be challenging in stop and go rush hour traffic.,,,,,,,,

I don't know if it would be damamging or not to ride with the clutch release lever loose, but my guess is it probably wouldn't.

Good luck.

And welcome to the forum.
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post #3 of 6 Old 10-26-2008, 04:47 PM
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Rotate the arm farther to the rear then push it down into the case.
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post #4 of 6 Old 10-26-2008, 07:11 PM Thread Starter
 
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Quote:
Originally Posted by SLO-KLR View Post
Rotate the arm farther to the rear then push it down into the case.
I'm not too sure what you mean. The range of rotation is about 50˚. When I rotate it out it drops down as seen it the first pic. When I rotate it in it jumps 2 millimeters up at around 23˚ before it hits the point of being flush with the boot and won't rotate any further, as seen in the second pic. Hence, when it is
rotated further to the rear it sits all the way in and can not be pushed any further. Keep in mind it can be pulled all the way out, and that is why I am wondering if I have to remove the case to get it to set correctly:

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post #5 of 6 Old 10-26-2008, 08:01 PM
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I just took a quick look at mine and a 2mm space is about right so you had it in correctly. There is no need to pull the case. You can't install that arm with the case removed. Once you have it turned forward to it's normal operating position it should lock in place. Your second pic in the first post is how it should look.

Last edited by SLO-KLR; 10-26-2008 at 08:07 PM.
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post #6 of 6 Old 10-26-2008, 08:30 PM Thread Starter
 
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Quote:
Originally Posted by SLO-KLR View Post
I just took a quick look at mine and a 2mm space is about right so you had it in correctly. There is no need to pull the case. You can't install that arm with the case removed. Once you have it turned forward to it's normal operating position it should lock in place. Your second pic in the first post is how it should look.
Good, now all I gotta do is order my "Terminator" cable . Thanks for the help.
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