Clutch Cable Routing - Kawasaki KLR 650 Forum
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post #1 of 9 Old 12-27-2015, 02:22 PM Thread Starter
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Clutch Cable Routing

2016 Model KLR650

I have a noise and rubbing issue that Iíve isolated to the clutch cable routing directly in front of the steering head. I note that thereís a metal retaining ring on the front of the steering head directly below the key-switching assembly. Thereís nothing going through it. Does anyone know if the clutch cable is supposed to go through there? Maybe take a peek for me?

I've been through the Service Manual for this model and donít see that metal retaining ring in any of the cable routing diagrams. The cable looks properly routed based on the Service Manual, but then Iíve got the noise and rubbing which just canít be right.




The closest I came to something similar to this issue searching the forum was the thread linked below. It addresses cable damage in a 2012, but this guy didnít mention the metal retaining ring or whether the cable should have been routed through it.

http://www.klrforum.com/2008-klr650-...ur-cables.html
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post #2 of 9 Old 12-27-2015, 04:11 PM
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Bill10,
Both the 2015 and 2009 which I have just looked at are routed exactly like yours (best I can see).
The 2009 has a 3 inch long 'paint-less' polish mark on the fairing support bracket and a little dirty, 'no squeak'.
The 2015 new and mostly clean, squeaks.

Even tho the wire guide is not shown in the cable/wire/ hose routing pages in the OEM service manual it is welded onto both year bikes. And "nothing goes thru it" on either year bike.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 9 Old 12-28-2015, 07:38 AM Thread Starter
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Ah, thanks. I'll just keep an eye on things.
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post #4 of 9 Old 12-28-2015, 02:17 PM
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Mine rubbed down to the cable sheath. ('09)

Replaced and rerouted it Ran it up between the tank and forks then left through the
bars (main bar and cross brace) over to the lever. Had to do that also for more
cable slack due to to the risers.

You can stare down the front while working the steering and see a few spaces where
nothing will hit the cable. There's nothing in my welded loop either and never was.
Weird.

This is my son, with whom I am well pleased." ----God
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post #5 of 9 Old 12-29-2015, 06:50 AM Thread Starter
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As best I can tell, that retaining ring is a big part of the problem with the rubbing of the clutch cable on the support bracket. It doesn't slide in above it and loses too much slack going under. Maybe actually routing the cable through it would be better. If not, then buzzing it right off altogether will certainly cure the problem.
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post #6 of 9 Old 10-13-2016, 08:08 PM
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Bill10, did you route the clutch cable through that loop? I have the same problem, as mine is showing the same rub as in that picture. Did you also route the electrical connection through it too? I started investigating this problem as I had a squeak. I Have a 15' and mine has nothing going through that metal loop.
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post #7 of 9 Old 10-14-2016, 05:56 AM Thread Starter
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I ended up cutting the loop off the tube, which seemed to cure the problem.
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post #8 of 9 Old 10-14-2016, 08:27 PM
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Thanks for the reply. I couldn't get myself to do the same. Though I think you nailed it. It leaves me wondering why that bracket is there in the first place. But I pulled the clutch cable out and saw where it had the rub marks on it. I then wrapped black electrical tape around that area. That seems to have stopped all the sqeaking. .
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post #9 of 9 Old 04-02-2018, 11:42 AM
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guys I am having this issue right ow with my 2018. my cable was routed thru the wire loop(welded to steering head) and w in 300 miles it was chafed all to crap. So then I had em route it out of the ring(warranty work) and it was fine. It would make the rub noise as described above but I put a little grease on the instrument panel support and that stopped it. I am wondering if that wire ring is there as a "bump Out" or slack remover for the cable. I do not believe the cable is to go thru there????????

Bike is at shop now. Evidently this cable chafing issue has been around for a while.....they are gonna try running cable both ways and see whats best. any input would be great
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