3rd bike, 1st KLR, need help - Kawasaki KLR 650 Forum
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post #1 of 3 Old 03-25-2015, 10:27 PM Thread Starter
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Join Date: Mar 2015
Location: Atlanta Ga
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3rd bike, 1st KLR, need help

1st post, new to the forum.

I have a 2001 KLR650, I've had it for about 6 months, it's my 3rd motorcycle, I love it.

Just recently got a membership to a co-op shop here in East Atlanta, and replaced my clutch plates, battery, clutch cable, clutch lever, removed the rear rack and windscreen, and some other odds and ends.

I'm not new to mechanical work, but it was surely a challenging and frustrating job, but you gotta learn somehow.

Today was the first time I'd been able to ride my bike in like 2 months, and I was ecstatic to do so.

****in kickstand down switch thingy had us stumped (because I forgot about it lol ) , we couldnt get into gear without stalling the bike with the brand new clutch in, and the lever pulled in.

Finally figured it out and off I went

I have big plans for this bike, can't wait to get back to work on it!


One major problem I have : the clutch cable gets routed underneath the headers and heat shield, but when it's there, it starts to melt. The old one was almost melted completely, and the brand new one is already starting to melt after today :/ .

Any tips on how to avoid this? I was gonna take the heat shield off of the header but it seems to be blocking the rear brake stuff from heating up, as well as a small bit of header wrap in that area.

I discovered I could pull a bit more slack out so the cable doesn't touch the header, so I was thinking I could do 1 of 2 things, either:

A - take off the heat shield and wrap the headers with thermal tape

B - Wrap some aluminum tape around the clutch cable itself

Not sure what to do about this, clutch cables are only $10, but I JUST put it in today and don't wanna have to wait for any other parts, or waste money.

If I wrap the cable in aluminum tape would this make it retain more heat, thus making it melt more?



Thanks for any suggestions
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post #2 of 3 Old 03-25-2015, 11:05 PM
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Is your clutch cable routed, down the frame tube, between the water hoses, to the clutch release lever on the RH case?
Does the bike have 'bar risers' or non-standard handlebars of any kind?

pdwestman
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Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 3 Old 03-25-2015, 11:45 PM Thread Starter
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Join Date: Mar 2015
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Quote:
Originally Posted by pdwestman View Post
Is your clutch cable routed, down the frame tube, between the water hoses, to the clutch release lever on the RH case?
Does the bike have 'bar risers' or non-standard handlebars of any kind?
I didn't go in between the water hoses.

Bars are stock as far as I know. Tried to contact PO recently, no luck.

I'll check it out tomorrow at the shop
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