Help! Clutch Sticking... - Kawasaki KLR 650 Forum
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post #1 of 4 Old 04-29-2008, 05:19 AM Thread Starter
 
Join Date: Apr 2008
Posts: 75
Unhappy Help! Clutch Sticking...

OK...this is weird! I ride daily, rode home last night, no issues, nothing.

When I rode in this morning, the clutch started to not let out all the way about a 1/4 into my commute, then it got worse and worse to where I had to PULL the clutch out to get it to engage.

Stalled in the middle of a road, had to finesse my way onto base (almost stalled at the guard gate of Camp Lejeune...nice.) But I wasn't anywhere I could turn around.

Nothing changed other then it rained on my coming home last night - feels like the cable is stuck in glue. Lubed and set the free play last week, like Monday and road every day...in and out of rain all last week.

I am stuck at work for now, afraid to ride the bike...it is that bad.

In the 60's and dry this morning, not cold.

Any ideas??

Sean
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post #2 of 4 Old 04-29-2008, 10:34 AM
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Join Date: Nov 2007
Location: Corpus Christi, TX
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First thing comes to mind is cable or lever restriction of some type.

I don't know how much wrenching you want to do on base, but you might try backing off the cable adjuster at the engine end and disconnecting the cable there. Then you can tell if it's a cable/linkage problem or if it's internal.

Hopefully some of the more experienced guys will pick up on this soon and give better guidance.

Good luck.
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post #3 of 4 Old 04-29-2008, 10:39 AM Thread Starter
 
Join Date: Apr 2008
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Quote:
Originally Posted by BIGIRON View Post
First thing comes to mind is cable or lever restriction of some type.

I don't know how much wrenching you want to do on base, but you might try backing off the cable adjuster at the engine end and disconnecting the cable there. Then you can tell if it's a cable/linkage problem or if it's internal.

Hopefully some of the more experienced guys will pick up on this soon and give better guidance.

Good luck.
Lever restriction - BINGO, give the man a cigar!

Went out and checked the clutch at lunch, took of the hand guard off and checked the freeplay, was spot on but still klugy/still sticking.

Took the 12mm wrench from the tool kit and loosened the pivot pin that holds the top bolt for the hand guard and whammo, full range on the clutch lever. I guess I over torqued the thing when I lubed the cable last week.

Not sure why it took over a week to manifest...but I am leaving the guard off until I get home and do some more investigation.

Scared the crap out of me.

Sean
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post #4 of 4 Old 04-29-2008, 10:56 AM
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Join Date: May 2007
Location: Richmond, Ky
Posts: 1,980
Yeah I not had any experience with the clutch but was thinking maybe the clutch basket linkage there on the engine case myself or the cable binding..

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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