[Dubs2121]

I recently purchased a very low-mile 2012 KLR. One potential issue when releasing the clutch is the friction point is at the very end of the release (clutch lever all the way out).

Is there a way to adjust the friction engagement area to around 2/3 of the clutch range?

I hope I am making sense.

 

[banditcilik]

Give the clutch cable more slack by adjusting the dial on the lever

 

[Dubs2121]

Give the clutch cable more slack by adjusting the dial on the lever

I thought that doing this only adjusts the play (gap) in the clutch lever. So more slack should move friction point away from the very end of the release?

 

[banditcilik]

It gives more play and moves the engaging point closer to the grip

 

[Dubs2121]

Excellent! Easy fix. Thank you!

 

[PeteK]

A very good mod is to extend the clutch release lever (that's on on top of the clutch cover). Twin Headlight Ernie offers this service. If you can cut and weld, add 3/4" of metal to lengthen the arm. This both increases the length of the engagement, making it easier to control, and reduces the hand effort, which isn't very high on a KLR in the first place, but it just makes the clutch easier to modulate.

Here's a link at Tom Schmidt's "Souperdoo" site. While you're there, poke around his other articles. twin-headlight-ernie-s-clutch-arm-why-didn-t-i-do-this-years-ago

 

[mzebley]

+1 what Pete said. I just installed the Ernie Bell extended clutch arm and what an incredible difference. I followed the excellent write up on Souperdoo’s website (thanks Tom!). The best part of this mod is the extended friction zone, particularly during the initial engagement. I can tell this will really help when off road.

 

[Dubs2121]

Excellent! Easy fix. Thank you

+1 what Pete said. I just installed the Ernie Bell extended clutch arm and what an incredible difference. I followed the excellent write up on Souperdoo’s website (thanks Tom!). The best part of this mod is the extended friction zone, particularly during the initial engagement. I can tell this will really help when off road.

Great endorsement! I sent Ernie an email requesting that part. I could not find a website to purchase.

 

[mzebley]

I could not find a website to purchase.

Here is Tom's write up where I initially found out about the extended clutch arm.

And here is Ernie's KLR site.

 

[PeteK]

IIRC, you need to send him your old part, then he extends it and sends it back to you.

 

[Six8five]

Yep he doesn’t stock the parts .
Either mail yours and wait or find a used one and send it to him.

 

[mzebley]

It didn't take long, about 10 days total using USPS snail mail.