klr 650 clutch question/ help - 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 12 Old 10-17-2016, 01:23 AM Thread Starter
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klr 650 clutch question/ help

Ok let me start out by saying im new to the forums and the motercycle world. Im a mechanic by trade but never worked on a motercycle ever. I recently got a 91 klr 650 in a trade and want to start getting int riding and being a mechanic leaening to fix my own bike. Im having an issue that i need some advice on.

When i receved the bike it was not running. I was told by the preveous owner that he thought there was a leak in the water pump seal do to finding coolant in the crank case. I pulled the clutch cover and found that there was a crack in the cover where the oil seal meets the coolant seal. I bought a replacment cover and seals on Ebay for the same basic year as my klr 650 and after installing the cover with new seals began installing it on the bike.

I got it all put on and got to the point of installing the clutch rod and cant get it to stay in place. Every time id try to put tention on the rod with the clutch cable it pops out. I looked at my old cover and i saw that the "new" cover i bought was a lil different. Something i had overlooked before is that my old cover has a lil 8mm bolt that locks the clutch rod in place and my "new" cover dosnt.

So my question is are there 2 different types of clutch rods out there? Ive already tryed looking up the part but cant seem to fine any info indicating that there where two different types made over the years. I was told the cover i got will fit up to a 07 KLR 650 and it is an older cover because it does have to hole for the kick start witch to my understanding was discontinued sometime in mid 90's. So i dont know. Any help would be helpfull a part number to a reputable parts sight that ships to Alaska would be better.
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post #2 of 12 Old 10-17-2016, 02:29 AM
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At least two clutch levers in the Gen 1 bikes' time period, and three cases.

The replacement case you got is '96 and later. They kept drilling and plugging the hole for the kick start long after the option went away, so don't be fooled by the presence of the hole.

There was a clutch cover unique to '96 and then a clutch cover that was '97 to '07.

I think if you get a clutch lever for '97 and up that it should work. The clutch rod that the bottom of the lever lever hooks into has never changed.

Best source is ebay. Like this one. 2000 Kawasaki KLR 650 KLR650 Engine Motor Clutch Cable Wire Assembly Actuator | eBay and you get spare stuff with it.

I've never tried mixing and matching levers and covers, so I can't explain what is different and why your pre '96 lever won't work with a post '95 cover. I am presuming that it worked before, nothing got broken, and you're inserting the lever correctly.

Tom

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Last edited by Tom Schmitz; 10-17-2016 at 02:44 PM. Reason: changed 'clutch rods' to 'clutch levers'
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post #3 of 12 Old 10-17-2016, 02:56 AM Thread Starter
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Thatns for the reply. Yes i checked to see if it was installed right and it seats all the way in but wont lock into place at all. Even if i push the lever slightly forward it wants to rotate up and and out. So it sounds like ill have to be on the lookout for a clutch lever for that cover.
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post #4 of 12 Old 10-17-2016, 09:48 AM
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A suggestion: Check part numbers from fiche for model years: "View Parts Diagrams" on Kawasaki website, or . . . "OEM Parts" fiches from vendors, like BikeBandit.
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post #5 of 12 Old 10-17-2016, 07:47 PM
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abrough,
I'll bet the clutch actuator only climbs about 1/16th to 1/8th inch up from fully bottomed! Correct?

That is proper. The little 'Guide' bolt on the old cover held the actuator shaft at the proper altitude for the fork at the bottom to connect onto the button head of the pull rod protruding from the clutch pressure plate.

Put your bike together.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #6 of 12 Old 10-17-2016, 08:57 PM Thread Starter
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pdwestman,
The actuator pops up about an inch and i loose all tention and force whenever i apply force using the cable or by hand. It definatly is not staying in place as i can pull the rod up and out reguardless of witch way its facing. It feels like it will ceatch and begin pressing on the clutch pin but then it slips and moves freely left to right and up and down.

Last edited by abrough61786; 10-17-2016 at 08:59 PM.
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post #7 of 12 Old 10-17-2016, 10:36 PM
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Quote:
Originally Posted by abrough61786 View Post
pdwestman,
The actuator pops up about an inch and i loose all tention and force ------------ It feels like it will ceatch and begin pressing on the clutch pin but then it slips and moves freely left to right and up and down.
abrough,
A full inch?
Do you understand that the actuator arm PULLS on the 'clutch pin'? It does not Push.
Maybe you do need a '97 and up actuator arm, for some reason which I do not understand.
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post #8 of 12 Old 10-17-2016, 10:55 PM
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I don't understand why it won't work, either. I've never tried it, of course. Can't figure out why it would pop up.

Pictures would be great, abrough, if you can take some of the inside of the cover and of the lever that you have. PM them to me or send me a link and I'll post them for you.

Tom

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The kid poured him another straight rye and I think he doctored it with water down behind the bar because when he came up with it he looked as guilty as if he'd kicked his grandmother. -Philip Marlowe

'Why' and 'How' are words so important they cannot be too often used. -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
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post #9 of 12 Old 10-17-2016, 11:08 PM
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abrough,
Notice the TWO "A"s in the circle, if my link comes thru!
2003 Kawasaki KL650-A17 Clutch | Babbitts Kawasaki Partshouse

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #10 of 12 Old 10-17-2016, 11:18 PM Thread Starter
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pdwestman,

Sorry for the confution. When i said push on the pin i was refuring to me pushing on the actuator in the direction that the cable would pull it. Im biggining to think that the cover i bought is a 97-newer cover and wont work with the stock actuator from the 91. I found a actuator for sale and it was cheap so i bought it. Im hopeing that it will work. It does look different then my curent one so we will see. I got a good deal in trade for the KLR and im hope to learn alot over this winter while i mess around with it. We already have snow here in Alaska so im not planning on doing much riding and will have lots of time to find and fix its lil isses before summer hits. Luckly i have it parked in my storage unit right across the street from the shop i work at so i get time each day on lunch and weekends to pull it in the shop and use the tools. I dont know much about bikes and ill probibly make alot of dumb mistakes like buying the wrong cover but this will be a good bike to learn on and ill gain a better understanding of motercycle mechanics from it. I also bought a repair manule and also hope that i can get good advice from the forums. Hope to get some good use out of the bike on the jeep trails and if all works out i may even take it on a few long trips cross Alaska!
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