gen 1/gen 2 clutch cover gasket compatibility - 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 10 Old 11-21-2019, 07:33 PM Thread Starter
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Join Date: Nov 2016
Location: San Diego, CA
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gen 1/gen 2 clutch cover gasket compatibility

Clutch started slipping a few days ago, so I'm putting in new clutch springs sometime this next week. Gasket for the gen 1 clutch cover is $30 at my local dealer, with the gen 2 coming in at $16. As I understand it, all klrs use the same clutch cover design except for the kickstart bore being phased out on gen 2. Are there any other differences that would stop me from using a later year gasket on my 2006?

P/N 11060-1111 (2006 klr)
P/N 11061-0429 (2018 klr)
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post #2 of 10 Old 11-21-2019, 07:51 PM
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I'll suggest made in Japan vs made in Thailand. Use it if you can get it.

pdwestman
Modify at "YOUR OWN RISK"!

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

Last edited by pdwestman; 11-22-2019 at 11:07 AM.
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post #3 of 10 Old 11-22-2019, 05:28 PM
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If you have your clutch torn down that far why not replace all of the fibers, and maybe the steels? Can't imagine a reason not to.

I have found on my bikes factory clutch stuff is better quality than aftermarket. Except for my race Ducatis. In that case the factory wasn't quite as good as the multi-dollar race stuff.
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post #4 of 10 Old 11-22-2019, 08:51 PM Thread Starter
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Quote:
Originally Posted by ymracing View Post
If you have your clutch torn down that far why not replace all of the fibers, and maybe the steels? Can't imagine a reason not to.

I have found on my bikes factory clutch stuff is better quality than aftermarket. Except for my race Ducatis. In that case the factory wasn't quite as good as the multi-dollar race stuff.
New springs are $20, new clutch pack is like $100. In any case, I have a spare set of oem clutch plates that I'll throw in if the ones in the bike are out of spec.
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post #5 of 10 Old 11-22-2019, 09:03 PM
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Quote:
Originally Posted by insan3guy View Post
New springs are $20, new clutch pack is like $100. In any case, I have a spare set of oem clutch plates that I'll throw in if the ones in the bike are out of spec.
How many miles are on the bike & current clutch plates?
Any chance that the slipping was/is caused by a fraying cable snagging up and not fully re-engaging?

May I ask as to Exactly what engine oil you have been using?

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #6 of 10 Old 11-22-2019, 11:02 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
How many miles are on the bike & current clutch plates?
Any chance that the slipping was/is caused by a fraying cable snagging up and not fully re-engaging?

May I ask as to Exactly what engine oil you have been using?
48k on bike and bike's original clutch pack. Clutch basket off a '95. Slipping behavior isn't indicative of the cable I don't think; it has smooth action and the slipping is happening pretty regularly (on takeoff, upshift).

Rotella t6 (with the ma2 rating on the bottle) for as long as I've owned it (~30k miles)

edit: I also have a new clutch cable routed and ziptied in case this one is on its way out, but I don't think that's the case.
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post #7 of 10 Old 11-23-2019, 03:25 PM
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Clutches usually slip during acceleration in a higher gear when they are becoming "fooked".Slip at start and such when the cable is not properly adjusted or need to be replaced. Rotella R6 is fine, IMHO.
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post #8 of 10 Old 11-23-2019, 03:45 PM Thread Starter
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Quote:
Originally Posted by ymracing View Post
Clutches usually slip during acceleration in a higher gear when they are becoming "fooked".Slip at start and such when the cable is not properly adjusted or need to be replaced. Rotella R6 is fine, IMHO.
Should've clarified: it happens almost every upshift and also if I gun it too hard in 4th or 5th. Stock gearing, too.

I've owned 6 bikes including this one and I've never had a problem with rotella. No real reason to think it's the problem here
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post #9 of 10 Old 11-23-2019, 05:29 PM
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But I do have 85,000 + miles on my original clutch pack parts and have never had a hint of slippage.
And I occasionally have to abuse it in the Rocky Mtn rock piles that I ride through. I've used Kawasaki oil since new, with one exception early on, Golden Spectro Semi-Syn 20W50, 1 change only.

Be careful of re-torqueing the small parts.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #10 of 10 Old 11-23-2019, 09:37 PM
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To answer your question about gaskets, either gasket should work.
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