Clutch Question - Kawasaki KLR 650 Forum
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post #1 of 7 Old 07-05-2014, 12:35 PM Thread Starter
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Join Date: Oct 2013
Location: Florence, Alabama
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Clutch Question

The clutch cable on my 2012 broke with less than ten thousand miles. When I tried to replace the cable somehow the release lever came out of the case a little. Now when I try to install the cable, the lever will not budge even though I put it back in the case. It looks like it's all the way in, but I wonder if it is binding against something that it shouldn't be. Before I take the case off, is there a trick to get it in line?
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post #2 of 7 Old 07-05-2014, 12:56 PM
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It should not be all the way in. Rotate it pointing straight back and raise it up about 1/8" and then rotate it back forward to its normal position.

That should let the notch in the shaft catch the head on the through out bearing puller.
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post #3 of 7 Old 07-05-2014, 03:30 PM
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+1 on Gomotor's recommendation. Likely, most of us encounter that at least once.

Did the clutch cable break near the lever end? That's usually where I've seen.

I prefer a Yamaha ATV cable because it's a thicker cable and seems to feel like there's less drag.

Clutch cable Motion Pro 306-5029, Yamaha 5X6-26341-00

It requires removing the bracket at the engine end of the cable but not a big project.

Watch out for routing of the cable as I see them routed too close to the exhaust on many bikes. A common failure is because the cable housing is cooked/burnt by the exhaust heat.
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post #4 of 7 Old 07-05-2014, 04:05 PM
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With just a little lubrication on the ends including the barrel on the cable end in the lever it should last a long time. My first went 40K miles and the second is at 65K.
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post #5 of 7 Old 07-05-2014, 04:50 PM
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Likely everyone already knows but the clutch lever, brake lever and brake pedal pivots are usually dry as popcorn and full of aluminium oxide. Pulling them apart, cleaning and some good waterproof chassis grease does wonders for both wear & application effort. The improvement in braking at front and clutch action can be graphic.
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post #6 of 7 Old 07-05-2014, 05:30 PM Thread Starter
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Join Date: Oct 2013
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Thanks for the quick responses. I think when the cable broke, the lever sprung out of position.
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post #7 of 7 Old 07-06-2014, 10:56 AM Thread Starter
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It's fixed! Thanks for the help.
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