KLR 650 clutch problem?

[johnniekombat]

I just bought a 2002 KLR, and when I have the clutch lever fully on, with the engine off, the bike does not roll freely like I think it should. It is still acting like it is in gear. Als, if I try and start the bike with it in gear with the cluth lever pulled it wants to lurch. Is this just a clutch adjustment needed or is my clutch hooped?

When the bike is in neutral it rolls freely with no restrictions.



Any help is appreciated. Thanks.

 

[dooveman]

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OK, can you start in neutral and then shift gears and use the clutch as it should be used? Like, is your bike actually not operating? Or are you just pointing out that it works but you notice this wierd behavior?

The reason I ask is that my bike is one year old and works fine. But one thing to note is that if you shut off the engine in gear, then pull in the clutch and expect it to roll it won't at first. You need to rock it back and forth for it to disengage.

Also, if you start it in gear with the clutch pulled in after stopping with it in gear it will lurch forward but not take off.

I think this has to do with the clutch sticking a bit and needs to be in motion to free itself like it is when you are travelling. So my assumption was it was totally normal.

Now if your bike doesn't disengage after rocking or won't disengage when shifting then ya it's busted.
Brian

 

[Pirate]

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More than likely it just requires a simple adjustment. If you have the handbook or a shop manual it will indicate the correct amount of free play at the lever. Check this and make sure that there is not too much free play, otherwise the clutch plates will not seperate adaquately and will drag. Also, remember that a motorcycle that is not running and in gearwill betypically harder to roll, as the plates tend to stick togethera little more and have less oil around them. If the engine is cold, again the bike will tend to want to lurch as you press the starter button, due to the aformentioned. Try it again after the adjustment and with the engine warm...:ted:

 

[johnniekombat]

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Ok thanks. The bike seems to operate fine when I am up an running. But dont remember my 01 CBR F4i grabbing like that at all. I think it may need an adjustment, but glad to hear its not hooped.

Thanks

 

[ZED]

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The KLR seems to like to do that. When I start mine after it's sat cold, I have to start it in neutral, then hold the front brake HARD while I thump it in gear. It will stall the first time. Then put back in neutral and start again. Now the clutch has come free and it will go in gear and even roll fine. It just seems to be a first time cold thing.

I first learned about this in the KLR FAQ
http://www.bigcee.com/klr650faq.html

I'd say if it's consistantly sticking hard even after warmup, you have a problem. If it's just dragging, don't worry about it.

 

[vanmixman]

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I had the same problem. Burnaby Kawasaki told me this is normal for a KLR. It does not do it as much now though.

 

[Norm]

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It's normal for a KLR to be tough to push while in gear with engine not running. The clutch simply doesn't disengage enough to allow easy movement between the friction and steel plates. It's the nature of the beast and indicates no problem. If you need to push it, you will need to take it out of gear.

HIH

Norm

 

[flip-flop]

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Mine has been the same, I start the bike in neutral and let it idle for a few min. then rev it a little while moving the clutch in and out. this seams to free the clutch and no lurching. Sticks more the longer the bike sits in damp and cool weather.

 

[Pirate]

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ZED wrote:

The KLR seems to like to do that. When I start mine after it's sat cold, I have to start it in neutral, then hold the front brake HARD while I thump it in gear. It will stall the first time. Then put back in neutral and start again. Now the clutch has come free and it will go in gear and even roll fine. It just seems to be a first time cold thing.

I first learned about this in the KLR FAQ
http://www.bigcee.com/klr650faq.html

I'd say if it's consistantly sticking hard even after warmup, you have a problem. If it's just dragging, don't worry about it.

Before engaging first gear with a cold engine, just hold the clutch lever in for about 15 seconds and it should then engage smooth as a babies bum.

 

[04klr]

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cough cough bulls*** cough cough, warm it, pump the lever, hold it in, it'll still lurch into gear, it's the little things that make it a KLR, and we still loves it don't we. ;} it'll do it when new, and do it when long in the tooth,

 

[tomcycle]

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Your bike should roll freely but will a slight drag (because you are turning all the gears)

Most likely your clutch basket is warn. Little notches in the basket that do not allow the clutch-plates to disengage completely. You will probably notice that with the engine running in gear that there is a slight drag on the drive-train. (the bike wants to move forward with the clutch disengaged)

This is usually found on high mileage bikes, but can be caused by the clutch cable adjusted to tight, dragging the clutch while stopped (we do that a lot off road riding)

The only solution I found is to replace the inner and outer baskets. Expensive. To help I would run synthetic oil, heavy oils will only make it worse.

I have ad success in the past by removing the baskets and filing the notches out, but this is as big job and not recommended.

If you are not sure what I am talking about I can probably post pictures of past baskets I have replaced



TT

 

[edzzed]

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if the bike sits for a while like a few days the clutch plates will oooze the oil out of the clutch and the plates will stick a bit. i notice after mine sits a few days without starting it when i run the engine and put it in 1st it will stall. need to unstick the clutch plates.

 

[cumminscowboy]

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If it makes you feel better my DRZ 400 has been doing it since brand new. Dosen't mean its right though.:?

Wil:hb:

 

[04klr]

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uh oh, I have one of each (klr,klx(drz))the klr sticks the klx never, sounds like you MAY have a problem with yur drz.

 

[cumminscowboy]

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I seem to have a problem with alot of things i own!It probably is just an adjustment but that means i would have to clean the bike to find the adjustment.it still goes forward and stops and falls on its side just as easy if not easier so i'm happy.

Wil:hb:

 

[Pirate]

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04klr wrote:

cough cough bulls*** cough cough, warm it, pump the lever, hold it in, it'll still lurch into gear, it's the little things that make it a KLR, and we still loves it don't we. ;} it'll do it when new, and do it when long in the tooth,

Not so my friend. If the clutch is pooched maybe, or the choke is revving the engine a little,but on an OK clutch, no clunking, lurching or mashinginto gear is normal.Sounds like you may need to make to make an adjustment !!!