Is my clutch destroyed? - Kawasaki KLR 650 Forum
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post #1 of 19 Old 09-14-2014, 10:26 AM Thread Starter
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Is my clutch destroyed?

Went to ride my klr the other day and noticed that after i put it in gear the bike wouldn't go. Its a 07 with 3k on it, The day before I was riding and it had a horrible acceleration, So I check the carb diapharm looking for pinch marks or pinholes, found none so I thought it was just bad gas til the next day when I was getting ready to go ride, thats when it wouldn't disengage. What are your thoughts? Do I need to rebuild the clutch on an 07 with so little miles? Before this it was fine, It's like it just happened at out of nowhere.
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post #2 of 19 Old 09-14-2014, 11:24 AM
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More information is needed and terms need to be straightened out.

A clutch is 'engaged' when the disks are held together by the pressure of the springs on the pressure plate. When the clutch lever is not pulled in, the clutch is engaged.

A clutch is 'disengaged' when the pressure plate is forced way from the disks so that they are free of one another. When the clutch lever is pulled in, the clutch is disengaged.

You say it won't go and that the day before it had horrible acceleration. Is the engine turning at high RPM and the bike just won't go?

Or is it bogging with no power?

If the engine is racing and this happened suddenly you should inspect both ends of the clutch cable to look for some kind of binding that would prevent the clutch cable from allowing the clutch to engage. Repeatedly squeeze the clutch lever and observe the actuating lever down by the clutch housing. It should move back and forth with every squeeze of the clutch lever.

The normal position for the clutch actuating lever has the lever at about 90 degrees to the clutch cable.

The clutch lever should have a wee bit of slack in it before it pulls on the clutch cable.

Can you check all of the above and get back?

Tom

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post #3 of 19 Old 09-14-2014, 11:46 AM Thread Starter
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seems to be stuck

You say it won't go and that the day before it had horrible acceleration. Is the engine turning at high RPM and the bike just won't go? YES

Or is it bogging with no power? NO

If the engine is racing and this happened suddenly you should inspect both ends of the clutch cable to look for some kind of binding that would prevent the clutch cable from allowing the clutch to engage. Repeatedly squeeze the clutch lever and observe the actuating lever down by the clutch housing. It should move back and forth with every squeeze of the clutch lever. Yes the actuator moves when i squeeze the clutch

Can you check all of the above and get back? Wont be home til tuesday so i'd have to llok at the cable again then.
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post #4 of 19 Old 09-14-2014, 11:51 AM
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OK. It's very unusual for a KLR clutch not to last for the life of the bike. If the cable is moving the arm and the cable has a bit of slack in it, the clutch should engage just fine.

Tom

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post #5 of 19 Old 09-14-2014, 11:53 AM Thread Starter
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I guess Ill just by a clutch rebuild kit just in case
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post #6 of 19 Old 09-14-2014, 11:56 AM
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Hi Kbar!
You need to check the clutch lever movement to ensure there is freeplay in the cable. You should be able to move the lever a short distance without moving the cable. This is so that when the lever is released it is NOT still pulling on the cable. If there is no freeplay the clutch is not being allowed to engage and is slipping as a result.
Have you recently done any adjustments or is there someone who may be fiddling with your bike?
Regards....justjeff

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post #7 of 19 Old 09-14-2014, 12:07 PM
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It shouldn't happen in such a short time but I wonder if the cable has frayed inside the tube and is not allowing the lever on the case to return properly. Check for freeplay at the lower lever as well. There should be a small amount of movement before resistance is felt when the slack is taken up.
jj

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post #8 of 19 Old 09-22-2014, 10:31 PM Thread Starter
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that cable was just slightly broken inside the tube, so it was stretching everytime i sqeezed the clutch

Last edited by klr4evr; 09-23-2014 at 05:41 PM.
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post #9 of 19 Old 09-22-2014, 10:43 PM
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Glad you got that sorted... This brings me to a question.. My clutch is not slipping, or anything like that, but there is little action in the lever. Do the cables just get stretched out over time? I was thinking I should replace the clutch springs and plates, but maybe I should just replace the cable. The current cable has about 20k miles on it.

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post #10 of 19 Old 09-22-2014, 10:55 PM
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Hi Cabrito!
What do you mean by "little action in the lever"? Is the clutch not disengaging when you pull the lever? If the clutch is not slipping there is no problem with the plates or springs.
jj

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Last edited by justjeff; 09-22-2014 at 10:59 PM.
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