The factory specifies so much movement as measured at the end of the lever. ( Sorry for the imprecision , I m currently traveling without a KLR manual)
But it s hard to make that measurement at the end of the lever. I ve found that a $0.25 piece (a quarter) makes a great adjustment gage if the measurement is made between the lever and the end of the clutch perch housing. You should have about a quarter s worth of freeplay before clutch engagement.
A precision clutch adjustment gage for $0.25, delivered, is somehow apropos of the frugality of the humble KLR.
From:
DSN_KLR650@yahoogroups.com [mailto:
DSN_KLR650@yahoogroups.com]
Sent: Sunday, October 26, 2014 8:04 PM
To:
DSN_KLR650@yahoogroups.com
Subject: [DSN_KLR650] Re: Clutch lever play: How much is too much?
This is weird: the bike definitely flunked this "drag test" (for lack of a better name) with the extra play. But that was new. The drag was so severe that I can't believe I've been riding with it like this and not noticed. And, when I adjusted it to spec (lower adjustment in the middle, 2-3 mm at the pivot), it dragged just as badly. I double-checked the adjustment. I'd already lubed the cable and checked for routing and fraying. I took it off and compared it to a new Motion Pro one, could see no difference. I installed the new one, which didn't help.
The distance the cable pulls the release lever is 11mm (measured where the cable attaches to the release lever). That seems plenty to separate the disks. With the cable disconnected I tried to work the release lever by hand, hoping to see if its total travel was more than 11mm: the springs are too strong for me to do that.
I'm at the end of my expertise (not a long trip).
-JW
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