Wilsons Sandbox

Posted: **Sat Oct 04, 2014 11:51 pm**

Spec is 2-3 mm at the perch pivot. (1) I like more, maybe 8mm, so that the clutch engages while the lever s closer to the grip. But the cable doesn t travel as far that way, so the plates don t separate as far. (2) I also have a lengthened release lever (from Fred). The longer lever decreases pull weight, but it doesn t rotate the shaft as far as the shorter stock lever does, so the shaft doesn t pull the lifter (rod) out as far, so again, reduced plate separation.

I get no drag with this setup. The only time it doesn t release is the first shift into first on a cold morning; the longer I warm up, the less it does it. But the mechanic insists I m wearing out the clutch doing this. Any thoughts?

-JW

Posted: **Sun Oct 05, 2014 12:03 am**

With your bike warmed up, in gear with the motor off, are you able to push the bike easily by hand with the clutch pulled in? If there is too much drag to push your bike, then you may need less free-play in your clutch cable. Fred http://www.arrowheadmotorsports.com [b]From:[/b] DSN_KLR650@yahoogroups.com [b]Sent:[/b] Saturday, October 4, 2014 10:51 PM [b]To:[/b] DSN_KLR650@yahoogroups.com [b]Subject:[/b] [DSN_KLR650] Clutch lever play: How much is too much? Spec is 2-3 mm at the perch pivot. (1) I like more, maybe 8mm, so that the clutch engages while the lever s closer to the grip. But the cable doesn t travel as far that way, so the plates don t separate as far. (2) I also have a lengthened release lever (from Fred). The longer lever decreases pull weight, but it doesn t rotate the shaft as far as the shorter stock lever does, so the shaft doesn t pull the lifter (rod) out as far, so again, reduced plate separation. I get no drag with this setup. The only time it doesn t release is the first shift into first on a cold morning; the longer I warm up, the less it does it. But the mechanic insists I m wearing out the clutch doing this. Any thoughts?

-JW

Posted: **Sun Oct 05, 2014 12:12 am**

Thanks Fred, that's another test that it passes just fine with my setup. I think I'll stop fretting about it....

Posted: **Sun Oct 05, 2014 8:36 am**

As long as your clutch is disengaged it doesn t make too much difference where your clutch lever is. The only issue I can think of is that on some that still have the clutch safety switch active, this switch may not function if your clutch lever has excessive free-play and doesn t push on this switch enough. Fred http://www.arrowheadmotorsports.com [b]From:[/b] DSN_KLR650@yahoogroups.com [b]Sent:[/b] Saturday, October 4, 2014 11:12 PM [b]To:[/b] DSN_KLR650@yahoogroups.com [b]Subject:[/b] Re: [DSN_KLR650] Clutch lever play: How much is too much? Thanks Fred, that's another test that it passes just fine with my setup. I think I'll stop fretting about it....

Posted: **Sun Oct 05, 2014 9:38 pm**

Posted: **Sun Oct 26, 2014 8:04 pm**

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

Posted: **Sun Oct 26, 2014 8:18 pm**

I should have said it USED TO pass this test. No longer. Mike Huber's post reminded me of something: Before this clutch problem started, I had the shop do the valves (next time I'll have enough time and courage to do it myself). They changed the oil too, draining my T6 and putting in- I don't know. They put enough in, per the slight glass. Perhaps I'll put the T6 back in and see whether the clutch frees up, but it's hard to see how the oil could cause that much drag.

-JW

Posted: **Sun Oct 26, 2014 8:31 pm**

Posted: **Sun Oct 26, 2014 9:01 pm**

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 ---------- ---------- ---------- [Non-text portions of this message have been removed]

Posted: **Sun Oct 26, 2014 9:29 pm**

#ygrps-yiv-1236007507 .ygrps-yiv-1236007507ygrp-photo-title { TEXT-ALIGN:center;WIDTH:75px;HEIGHT:15px;CLEAR:both;FONT-SIZE:smaller;OVERFLOW:hidden;} #ygrps-yiv-1236007507 DIV.ygrps-yiv-1236007507ygrp-photo { BORDER-BOTTOM:black 1px solid;BORDER-LEFT:black 1px solid;BACKGROUND-COLOR:white;WIDTH:62px;BACKGROUND-REPEAT:no-repeat;BACKGROUND-POSITION:center 50%;HEIGHT:62px;BORDER-TOP:black 1px solid;BORDER-RIGHT:black 1px solid;} #ygrps-yiv-1236007507 DIV.ygrps-yiv-1236007507photo-title A { TEXT-DECORATION:none;} #ygrps-yiv-1236007507 DIV.ygrps-yiv-1236007507photo-title A:active { TEXT-DECORATION:none;} #ygrps-yiv-1236007507 DIV.ygrps-yiv-1236007507photo-title A:hover { TEXT-DECORATION:none;} #ygrps-yiv-1236007507 DIV.ygrps-yiv-1236007507photo-title A:visited { TEXT-DECORATION:none;} #ygrps-yiv-1236007507 DIV.ygrps-yiv-1236007507attach-table DIV.ygrps-yiv-1236007507attach-row { CLEAR:both;} #ygrps-yiv-1236007507 DIV.ygrps-yiv-1236007507attach-table DIV.ygrps-yiv-1236007507attach-row DIV { FLOAT:left;} #ygrps-yiv-1236007507 P { PADDING-BOTTOM:3px;PADDING-LEFT:0px;PADDING-RIGHT:0px;CLEAR:both;OVERFLOW:hidden;PADDING-TOP:15px;} #ygrps-yiv-1236007507 DIV.ygrps-yiv-1236007507ygrp-file { WIDTH:30px;} #ygrps-yiv-1236007507 DIV.ygrps-yiv-1236007507attach-table DIV.ygrps-yiv-1236007507attach-row DIV DIV A { TEXT-DECORATION:none;} #ygrps-yiv-1236007507 DIV.ygrps-yiv-1236007507attach-table DIV.ygrps-yiv-1236007507attach-row DIV DIV SPAN { FONT-WEIGHT:normal;} #ygrps-yiv-1236007507 DIV.ygrps-yiv-1236007507ygrp-file-title { FONT-WEIGHT:bold;} #ygrps-yiv-1236007507 #ygrps-yiv-1236007507ygrp-mkp { BORDER-BOTTOM:#d8d8d8 1px solid;BORDER-LEFT:#d8d8d8 1px solid;PADDING-BOTTOM:0px;MARGIN:10px 0px;PADDING-LEFT:10px;PADDING-RIGHT:10px;FONT-FAMILY:Arial;BORDER-TOP:#d8d8d8 1px solid;BORDER-RIGHT:#d8d8d8 1px solid;PADDING-TOP:0px;} #ygrps-yiv-1236007507 #ygrps-yiv-1236007507ygrp-mkp HR { BORDER-BOTTOM:#d8d8d8 1px solid;BORDER-LEFT:#d8d8d8 1px solid;BORDER-TOP:#d8d8d8 1px solid;BORDER-RIGHT:#d8d8d8 1px solid;} #ygrps-yiv-1236007507 #ygrps-yiv-1236007507ygrp-mkp #ygrps-yiv-1236007507hd { LINE-HEIGHT:122%;MARGIN:10px 0px;COLOR:#628c2a;FONT-SIZE:85%;FONT-WEIGHT:700;} #ygrps-yiv-1236007507 #ygrps-yiv-1236007507ygrp-mkp #ygrps-yiv-1236007507ads { MARGIN-BOTTOM:10px;} #ygrps-yiv-1236007507 #ygrps-yiv-1236007507ygrp-mkp .ygrps-yiv-1236007507ad { PADDING-BOTTOM:0px;PADDING-LEFT:0px;PADDING-RIGHT:0px;PADDING-TOP:0px;} #ygrps-yiv-1236007507 #ygrps-yiv-1236007507ygrp-mkp .ygrps-yiv-1236007507ad P { MARGIN:0px;} #ygrps-yiv-1236007507 #ygrps-yiv-1236007507ygrp-mkp .ygrps-yiv-1236007507ad A { COLOR:#0000ff;TEXT-DECORATION:none;} On 26 Oct 2014 18:04:05 -0700 "jwflower53@... [DSN_KLR650]" DSN_KLR650@yahoogroups.com> writes: 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 <><><><><><><> <><><><><><><> JW, If you put an adjustable wrench on the lever at the engine you can probably move it as much as you like. Best, Jeff Saline The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650 . . . . . ____________________________________________________________ [b]Odd Trick Fights Diabetes[/b] "Unique" Proven Method To Control Blood Sugar In 3 Weeks. Watch Video. DiabetesProtocol.com

Wilsons Sandbox

amendment: antigravity micro-start xp-1

clutch lever play: how much is too much?

clutch lever play: how much is too much?

clutch lever play: how much is too much?

clutch lever play: how much is too much?

clutch lever play: how much is too much?

clutch lever play: how much is too much?

clutch lever play: how much is too much?

clutch lever play: how much is too much?

clutch lever play: how much is too much?

clutch lever play: how much is too much?