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Old 11-23-2009, 05:14 AM   #1
Twin headlight Ernie OP
bar napkin engineering
 
Joined: Aug 2005
Location: Dakota Minnesota
Oddometer: 1,385
2HE KLR650 clutch arm mod

Here's a picture of the 2HE clutch arm mod now available to the KLR650 owners of the ADV community. The stock factory arm is on the left and the 2HE clutch arm mod is on the right. The added length of the modded arm decreases the effort at the clutch lever, reducing fatique and makes the clutch much easier to operate. This mod works on both the new and old generation KLR650's. I have had this mod on my own KLR for 4 years now and consider it to be the best bang for the buck mod on the bike. If you've ever thought about a hydraulic clutch kit for your KLR this is a much less expensive solution. Cost is $35.00 plus exchange of your old clutch arm in good working condition.
You can reach me at: dakotabeemer@hotmail.com
More products and pictures can be seen on my smugmug at: www.twinheadlighternie.smugmug.com
Thanks for your support. 2HE

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Old 11-23-2009, 07:26 AM   #2
Thraan
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I am definitely interested. How hard is it to install? Do you have installation instructions?
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Old 11-23-2009, 03:11 PM   #3
Twin headlight Ernie OP
bar napkin engineering
 
Joined: Aug 2005
Location: Dakota Minnesota
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KLR650 clutch arm

Hi Thraan,
The clutch arm is a very easy installation. Remove the cable at the clutch arm. Clean the area around the shaft seal so no dirt drops in. Rotate the clutch arm counterclockwise about a 1/4 turn and it will lift right out. Install the new arm and readjust the cable to spec. It's about as simple as it gets.
Thanks for asking. 2HE
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Old 11-23-2009, 03:30 PM   #4
Thraan
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Sweet! I will talk to a buddy here who also has a KLR and see if he wants one too.

Thanks!
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Old 11-29-2009, 07:11 PM   #5
DirtyDog
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2HE- First off, kudos for stepping up on producing this mod. I've wanted one for years.

Second, a proposition... Are you willing to discount the purchase price if I send you 2 "cores" and only expect one in return? I figure you could use a couple extra for inventory purposes.

Thanks in advance.
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Old 11-30-2009, 08:57 AM   #6
R_W
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Quote:
Originally Posted by Twin headlight Ernie
Hi Thraan,
The clutch arm is a very easy installation. Remove the cable at the clutch arm. Clean the area around the shaft seal so no dirt drops in. Rotate the clutch arm counterclockwise about a 1/4 turn and it will lift right out. Install the new arm and readjust the cable to spec. It's about as simple as it gets.
Thanks for asking. 2HE
That's it??? and I have ignored my slowly leaking seal

Is there any adjustment to the cable mount?
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Old 11-30-2009, 05:48 PM   #7
Twin headlight Ernie OP
bar napkin engineering
 
Joined: Aug 2005
Location: Dakota Minnesota
Oddometer: 1,385
clutch arm mod

Hey DirtyDog, Sounds like good plan. Sent you a PM

Hey RW, The arm itself is the same as the stock one only a touch longer to decrease the effort needed. The adjustment comes at both ends of the clutch cable. Just adjust it the same way as the stock arm. (with a touch of free play at the lever) This is also a good time to lube or replace the cable and lube the pivot at the clutch lever. 2HE
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Old 12-02-2009, 06:48 PM   #8
Twin headlight Ernie OP
bar napkin engineering
 
Joined: Aug 2005
Location: Dakota Minnesota
Oddometer: 1,385
KLR clutxch arm mod

Just a quick note to let Sean know that his KLR clutch arm went out this morning. Please let me know how it works out for you. Thanks. Ernie
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Old 12-06-2009, 07:47 PM   #9
Armacham
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Thanks for this great product Ernie. I didn't really buy it for the reduced effort, although that is a bonus. My favorite part is that it makes the friction zone about a mile wide. I can't wait to see how this helps me on the slow stuff. I have a feeling that this mod + a 14tooth front sprocket could help the KLR really go places.

Installation was a cinch. I did have to slight adjust the angle of the adjustment guide that is bolted to the engine, so that the cable wasn't rubbing.

Also the rear master cylinder cover looks great!
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Old 12-07-2009, 05:39 PM   #10
Twin headlight Ernie OP
bar napkin engineering
 
Joined: Aug 2005
Location: Dakota Minnesota
Oddometer: 1,385
modified clutch arm

Thanks for the good report Armacham. The extra wide friction zone comes in handy when climbing hills and in the rough stuff. I hope it serves you well. Thanks again. Ernie
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Old 12-27-2009, 06:46 AM   #11
Twin headlight Ernie OP
bar napkin engineering
 
Joined: Aug 2005
Location: Dakota Minnesota
Oddometer: 1,385
KLR clutch arm mod

Just a note to thank the guys for sending back the clutch arm cores in short order. I have two arms on hand ready to go. 2HE
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Old 03-11-2010, 05:46 PM   #12
revmaaatin
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Location: Two seasons: winter and road repair
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Wink KLR Clutch mod

Quote:
Originally Posted by Twin headlight Ernie
Just a note to thank the guys for sending back the clutch arm cores in short order. I have two arms on hand ready to go. 2HE
Ernie,
What a great idea!
Looked at your other items as well--how many watts are you drawing with both big lights on, plus the pia = all the lights on? Do you describe this mod somewhere else, etc?
revmaaatin.
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Old 03-11-2010, 06:47 PM   #13
Twin headlight Ernie OP
bar napkin engineering
 
Joined: Aug 2005
Location: Dakota Minnesota
Oddometer: 1,385
Clutch arm mod

I've made a ton of mods to my KLR and the clutch arm mod is still my favorite. Best bang for the buck mod ever. I get a lot of complements on it.

My headlight setup has a 35 watt H4 bulb on one side and a HID on the other. The Piaa aux lights are 35 watt each as well. I added relays to all the lighting systems. I installed a LED voltage system monitor to help keep an eye on things. No problems even with the stock charging system. I really enjoy the extra light. It makes it more fun to ride at night. 2HE
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Old 11-19-2010, 03:56 AM   #14
Twin headlight Ernie OP
bar napkin engineering
 
Joined: Aug 2005
Location: Dakota Minnesota
Oddometer: 1,385
Clutch arm mod

Another klr clutch arm mod is on the way to CJ. Thanks. Ernie
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My Smugmug:
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Old 03-31-2011, 09:01 AM   #15
intotheabis
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Clutch arm

Hey Ernie, installed the clutch arm yesterday and took her for a boot. At first I thought the cable was broken!, WOW what a difference!
Thanks very much and keep up the good work!
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