KLR650 clutch adjustment

Discussion in 'Thumpers' started by cantrell, Dec 3, 2006.

  1. cantrell

    cantrell Rider and Writer

    Joined:
    Aug 25, 2006
    Oddometer:
    138
    Location:
    Northern Virginia
    I'm having trouble getting my clutch adjusted on my KRL. I broke my clutch lever, and since replacing it, I can't get it just how I want it. Adjusting it so that it engages sooner leaves it really loose and wobbly, and tightening it up makes it engage too late. I'd like to have it feel sturdy, and have it engage about halfway through being let out. Anyone have some pointers for me?

    Thanks,
    Christian
    #1
  2. Dolly Sod

    Dolly Sod I want to do right, but not right now

    Joined:
    Aug 18, 2003
    Oddometer:
    18,279
    Location:
    Richmond, Va
    I'm not sure you'll ever get it that way. Once the clutch engages there should be little room left until the end of travel. Just a little bit of slop with the lever competely relesed is correct clutch adjustment..
    #2
  3. Trailryder42

    Trailryder42 Long timer

    Joined:
    Oct 3, 2006
    Oddometer:
    1,065
    Location:
    Amarillo, Texas
    I don't like the KLRs clutch activation either. There are 2 ways to bring the activation closer to the lever pull range you want and they both also spread the clutch activation range from full engaged to disengaged over a wider lever pull range, which is great for feathering the clutch over difficult off-road terrain.

    This is the first method:
    http://klrworld.com/forums/index.php?topic=51.0

    The 2nd way would be to fit an MSR Raptor clutch lever and perch assembly and put the cable end in the lever hole closest to the lever pivot.
    #3
  4. pckopp

    pckopp Aged Adventurer

    Joined:
    Feb 25, 2003
    Oddometer:
    1,427
    Location:
    Seattle, WA
    Registration required to visit this link.

    It's hard to believe there is info about a KLR that is so secret, so valuable and so unique it is only available to a special few. Who would have thought; a forum created to keep information secret!
    #4
  5. Trailryder42

    Trailryder42 Long timer

    Joined:
    Oct 3, 2006
    Oddometer:
    1,065
    Location:
    Amarillo, Texas
    I know, it's getting to be a common thing anymore. But if you ride a KLR, it's probably one of the best forums around right now. So register.
    #5
  6. ldeikis

    ldeikis Dirty daydreamer

    Joined:
    Mar 30, 2005
    Oddometer:
    719
    Location:
    Peekskill NY
    I've never been to that site, but I'm impressed by this mod (and/or that there's farkle out there I wasn't aware of) so I registered and will check it out. The mod is, in essence, cutting the arm that the clutch cable connects to at its lower point and extending it a little bit. This means the cable (and therefore the lever in your hand) has to move more to get an equivalent amount of clutch engagement in the engine. Very clever.

    [​IMG]

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    If you're not a competent welder I wouldn't mess with it... not the kind of spot you want to break and it's under a lot of tension just there.

    These photos are from KLRCary at that site. Don't mean any disrespect by linking to them; we link to photos from other sites all the time. I just spent a minute perusing that site, it's (obviously) KLR only, but already has a lot of info up. Check it out.

    -Luke
    #6