Clutch cable ? - Kawasaki KLR 650 Forum
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post #1 of 5 Old 01-26-2019, 05:20 PM Thread Starter
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Join Date: Oct 2018
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Hi, I have owned my 2012 for a few months, and it now has 25k on it. My question is, how many of you, have replaced the clutch cable, around that mileage? I have pretty much ran out of adjustment, on both ends. It still has the required play, but has a lot of slop ( for lack of a better word) in it, and I push the lever forward, just to make sure, it has returned. Just seems like the cable has stretched, and needs replacement. I have ordered a factory cable, but am curious, if this is the norm.
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post #2 of 5 Old 01-26-2019, 05:41 PM
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I'll guess that when you remove your LH hand guard & lever to replace the cable you will find that it is almost completely broken, near the hand lever.

We really should clean and re-grease the lever pivots & the ends of the cables where it engages the lever once per year. When the 'cable toggle' is dry of lube, it doesn't swivel in the notch of the lever, it attempts to bend the cable wires. They don't like that! They tend to break their individual wires, one at a time.

Be certain to leave at least an 1/8th inch of cable slack as you readjust and that the lever pivot doesn't bind the lever.

pdwestman
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post #3 of 5 Old 01-26-2019, 06:00 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
I'll guess that when you remove your LH hand guard & lever to replace the cable you will find that it is almost completely broken, near the hand lever.

We really should clean and re-grease the lever pivots & the ends of the cables where it engages the lever once per year. When the 'cable toggle' is dry of lube, it doesn't swivel in the notch of the lever, it attempts to bend the cable wires. They don't like that! They tend to break their individual wires, one at a time.

Be certain to leave at least an 1/8th inch of cable slack as you readjust and that the lever pivot doesn't bind the lever.
Will do, is 25k about normal for replacement?
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post #4 of 5 Old 01-26-2019, 06:10 PM
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My current cable has 70K on it (transferred it over from my '08) and is in fine shape. To Paul's point - if it moves, lube it. Also pay particular attention to the housing alignment down at the clutch case. Ensure that the cable is not rubbing on the housing.

A clutch cable should last a very long time.

Tom [email protected]

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post #5 of 5 Old 01-31-2019, 02:23 PM
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Location: Texas
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Steel cables don't stretch. If it gets too loose or too tight, it is related to something at one of the ends. I don't oil the cable itself. Just the the fitting at each end and the lever pivots at each end. They last too long to keep track of, but I do still carry a spare on long trips for peace of mind.
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