klr600 1985 9000miles

[James A III]

Anyone ever worn out a clutch on their KLR? I got 34K and am thinkin' it may be time...

[cyclebay@aol.com]

48,000 miles and just replaced the clutch basket due to knocking in the lower end of the motor. Cush drive springs were beat until the basket had 1/4" of freeplay when rocked against the gear. Clutch had also reached a point where it was difficult to find nuetral when sitting stopped. Reinstalled the old clutch plates (originals) with the new basket and new clutch springs (pressure plate springs). Clutch basket solved the knocking. In fact, I purchased the bike ('04 with 8,200 miles) and it had this knock at highway speeds (80mph with luggage and passenger) since day one. Knock had gotten much worse as mileage has been added. With new clutch basket, knock is currently gone, vibration is reduced at all rpm's, nuetral is once more easy to locate when stopped. Doohickey has been in the bike since I bought it, installed by the prior owner. Replaced balancer chain at 35,000 (doohickey spring was not tensioning any longer and chain had tight and loose spots in it as all chains seem to do as they wear), installed new cam chain while doing the basket as tensioner was nearing the last 1/3rd of adjustment. Leaving for a 2,500 miles trip to Mid Ohio (Vintage Days) next Wednesday, followed by 2 days of backroad riding in West Virginia. No worries at this time. Greg ************************************** Get a sneak peek of the all-new AOL at http://discover.aol.com/memed/aolcom30tour [Non-text portions of this message have been removed]

[Bob Schulte]

When it doesn't work anymore replace it.

----- Original Message ----- From: James A III To: DSN_KLR650@yahoogroups.com Sent: Thursday, July 19, 2007 9:22 PM Subject: [DSN_KLR650] CLutch Wear Anyone ever worn out a clutch on their KLR? I got 34K and am thinkin' it may be time... [Non-text portions of this message have been removed]

[Jud Jones]

--- In DSN_KLR650@yahoogroups.com, "James A III" wrote:

> > Anyone ever worn out a clutch on their KLR? I got 34K and am thinkin' > it may be time... >

At 40k, I'm thinking mine's about done. First time I wore out a clutch on anything.

[Chris Long]

Hello all, I have a 2008 with close to 20,000 miles on it. I got it at 15,000 and the engagement point for the clutch has always been towards the end of the lever travel. I'm wondering if that is an indication that the clutch plates need replacement. Thanks for your help. Chris Lakewood, CO 2008 KLR Sent from my iPhone

On Jul 1, 2009, at 6:08 AM, Luc Legrain wrote: > > > > Looking for somebody " EXPERIENCED " 150 miles radius of Nashville, > Tn to help me check valves on my '05 bike . > Thanks > > [Non-text portions of this message have been removed]

[Jud Jones]

--- In DSN_KLR650@yahoogroups.com, Chris Long wrote:

> > Hello all, > > I have a 2008 with close to 20,000 miles on it. I got it at 15,000 and > the engagement point for the clutch has always been towards the end of > the lever travel. I'm wondering if that is an indication that the > clutch plates need replacement. > > Thanks for your help.

My engagement point has been near the end of the lever travel for the last 40,000 miles, and I assume for the 4k before that when I didn't own it. I get a little better control with my stubby fingers by adjusting the lever for a little extra free play.

[cyclebay@aol.com]

71,000 miles on original clutch on 2004 KLR650. Inspected two weeks ago and everything still looks good. I have replaced three cables. They run too close to the exhaust header, melt inside or condensate from the heating/cooling, then they don't relaease fully when the lever is released, then the clutch begins to slip gradually. By the time the rider notices the clutch slip, it has damaged the plates and is beyond a cable replacement. I lube my cable with a spray chain lube and a cable luber tool a couple times per year and I have zip tied the cable to one of the water pump hoses to keep it pulled away further from the header. I wrapped an old inner tube around the water pump hose and zip tied it to prevent the hose from being damaged from the vibrating zip tie that is holding the cable. I removed the cable periodically so that I can tell if it moves easily in and out by hand, with the variable of the motor actuator arm and the hand lever removed from the equation. As far as the lever freeplay goes, when the lever is pulled in far enough to remove all freeplay, there should be enough room to stick a nickle sideways (3-4mm)between the holder and the lever. More than that is Ok so long as the clutch dowesn't drag when fully pulled in, less is not good. Greg Hall

[transalp 1]

The jet kit is pretty straightforward. Clean the outside of the carb before you take it loose. No sense in letting dirt & debris mess up what is essentially a 5 min. job.(once the carb is in hand.) Take care with the rubber slide diaphragm and make sure it is seated properly when you put the top back on,too. Downstairs, carefully remove the float bowl on your way to changing the main jet. pay particular attention to the float assembly and not hit it on anything and possibly knock it out of adjustment. Aside from that, it's really simple. eddie

> [Original Message] > From: benji_sounds > To: DSN_KLR650@yahoogroups.com> > Date: 7/3/2009 6:39:42 AM > Subject: [DSN_KLR650] KLR600 1985 9000miles > > Ok so after alot of pissing about with the bike recently new front tyre

new front brake pads new starter clutch cleaning the carb due to a leak and overflowing. Ive now purchased a SuperTrapp IDS2 Racing Series and a DynoJet Stage 3 Kit, Which air filter should I fit and does anybody know if 650 airfilters fit on 600s. The 600 isn't quite as supported as the 650.

> > Also is the DynoJet kit a ballache to fit? Alot of pissing about? > > > Next in line is rear tyre and brake shoes then maybe sprockets and chain. > > > > ------------------------------------ > > List sponsored by Dual Sport News at: www.dualsportnews.com > List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html > Member Map at: http://www.frappr.com/dsnklr650Yahoo! Groups Links > > >