Worn Clutch ? - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 20 Old 12-20-2013, 01:33 AM Thread Starter
1st Gear
 
UKbri's Avatar
 
Join Date: Aug 2013
Location: The Black Hills
Posts: 49
Worn Clutch ?

My missus' 2010 KLR clutch seems to nearly be out of adjustment. It's done 25,000 miles. Seems a bit early for the clutch to be worn out as most of the miles have been on the highway. Is there a trick to get more life out of them or are they just done after that mileage ?
UKbri is offline  
Sponsored Links
Advertisement
 
post #2 of 20 Old 12-20-2013, 05:12 AM
5th Gear
 
Join Date: Jan 2011
Posts: 4,379
KLR650 clutches seem rather robust, from experience of others. Assuming the clutch hasn't been abused (as in, slipped excessively), I'd expect service life beyond 25,000 miles.

Regarding adjustment, the clutch cable is adjustable at BOTH ends, at handlebar lever and also at actuator lever. Have you exhausted adjustment at both these points?

Service manuals have service limits: 2.60 mm/0.102 in. friction plate thickness; 36.4 mm/1.43 in. spring length ('96-'07); steel plate warp 0.3 mm/0.012 in.

Don't know of any tricks for clutch life-extension; with components complying with these service limits, should be adjustable to serviceable condition, IMHO. Not terribly hard to check out (can be disassembled without removing crankshaft nut); not terribly expensive to replace parts.
Damocles is offline  
post #3 of 20 Old 12-20-2013, 10:30 AM
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,601
Garage
Very robust.

A partial list of bikes that use the same friction plates, all of which are far more potent than the KLR650:

KLX650
KZ550
KZ750
KZ1000
ZX600
ZX750
ZR1200

Properly used, the KLR650 clutch usually lasts for the life of the bike.

Damocles has pointed you in the right direction; check the lower adjustment.

Tom

Tom [email protected]

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
Tom Schmitz is offline  
 
post #4 of 20 Old 12-20-2013, 10:45 AM
1st Gear
 
shil's Avatar
 
Join Date: Aug 2013
Location: Uxbridge, Ontario
Posts: 50
Seems to me you're looking at a stretched cable. Rather than a worn clutch.
If the clutch isn't slipping I'd say it's OK.
shil is offline  
post #5 of 20 Old 12-20-2013, 01:03 PM
4th Gear
 
Join Date: Oct 2006
Location: Pefferlaw,Ontario
Posts: 1,636
I use the KZ1000 clutch springs in my stock clutch and haven't had a single issue with it yet after 80,000kms....I replaced it the minute I did my first 685 and engine build to follow KLRCary's recomendation. I never slip the clutch either .......more than normal that is.

Willys
willys is offline  
post #6 of 20 Old 12-21-2013, 01:16 PM Thread Starter
1st Gear
 
UKbri's Avatar
 
Join Date: Aug 2013
Location: The Black Hills
Posts: 49
Cheers guys. Good to know they are durable. I will have another pay with it
UKbri is offline  
post #7 of 20 Old 10-16-2017, 02:05 AM
Neutral
 
Join Date: Jul 2017
Posts: 12
Quote:
Originally Posted by Damocles View Post
KLR650 clutches seem rather robust, from experience of others. Assuming the clutch hasn't been abused (as in, slipped excessively), I'd expect service life beyond 25,000 miles.

Regarding adjustment, the clutch cable is adjustable at BOTH ends, at handlebar lever and also at actuator lever. Have you exhausted adjustment at both these points?

Service manuals have service limits: 2.60 mm/0.102 in. friction plate thickness; 36.4 mm/1.43 in. spring length ('96-'07); steel plate warp 0.3 mm/0.012 in.

Don't know of any tricks for clutch life-extension; with components complying with these service limits, should be adjustable to serviceable condition, IMHO. Not terribly hard to check out (can be disassembled without removing crankshaft nut); not terribly expensive to replace parts.
I've checked the service manual myself, and it shows 2.60mm as the service limit for the Clutch Friction plates. Reading this, and seeing that my friction plates were in the 2.22-2.25 range, I ordered brand new friction plates - EBC brand. I get them, and measure them and the brand new plates are 2.25mm thick. Is the Clymer service manual wrong? Any other sources for the minimum thickness on the friction plates. I'm just not believing the 2.60MM.
rgmr250 is offline  
post #8 of 20 Old 10-16-2017, 10:03 AM
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,601
Garage
According to the Kawasaki service manual, the service limit is 2.75mm. New would be 3ish mm.

2.25mm! HFS!
Attached Images
File Type: jpg Friction Plate thickness.JPG (45.5 KB, 6 views)

Tom [email protected]

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
Tom Schmitz is offline  
post #9 of 20 Old 10-16-2017, 11:07 AM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,604
What year and model are you working on rgmr250? What # of EBC plate kit did you receive?

OEM Base manual for KL650 A's 1987-2007 is the KL600 A manual.

It reads,
Standard---- 2.75-3.05mm ---- Service Limit--- 2.65mm

My 2014 Edition of Gen 2 manual for 2008 & up models reads,
Standard--- 2.90-3.10mm (0.114-0.122inch) --- Service Limit--- 2.7mm ((0.106inch)

Other than 2 or 3 replacement clutch cables, I've got over 80,000 trouble free miles on all my 1987 -A1 clutch parts.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is offline  
post #10 of 20 Old 10-16-2017, 11:46 AM
5th Gear
 
Join Date: Jan 2011
Posts: 4,379
As to the aftermarket clutch plate thickness . . . we do not know what clutch springs were assumed . . . possibly clutch springs of higher rate . . .

Then . . . if the clutch slips, you can always shim the clutch spring bolts with washers!

CAVEAT: An expedient advisable only if proper springs and/or clutch plates are unavailable.
Damocles 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 Removal / Clutch Holder cawoodm 1987 to 2007 Wrenching & Mods 28 04-15-2012 12:54 AM
Clutch life Aron31 2008+ KLR650 Wrenching & Mod Questions 1 01-08-2012 02:11 PM
clutch lasher KLR & Other Motorcycle Related Discussion 1 10-21-2010 12:07 AM
Clutch rocka KLR & Other Motorcycle Related Discussion 5 12-07-2009 09:22 AM
My bike. Is my clutch ok? tcbb32 1987 to 2007 Wrenching & Mods 4 03-28-2008 09:57 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