Kawasaki KLR650 Clutch Cable Replacement

All moving parts on a motorcycle wear out eventually, including clutch cables. 

Lubing the cables on your Kawasaki motorcycle should be part of its regular maintenance. A clutch cable can fray, snap or stretch out and bind in its housing. Once it stretches out enough that adjustment is no longer possible, or it becomes hard to pull in the lever or the clutch doesn’t disengage fully, it’s time to swap that cable out. 

Watch the video above and follow the steps below to replace the clutch cable on a Kawasaki KLR 650. 

Tools and Parts Needed – Kawasaki KLR650 Clutch Cable Change

Tools

  • Needlenose pliers
  • 12mm wrench
  • 8mm socket and ratchet
  • Extensions 

 

  • Electrical tape

Parts

 

Clutch cable replacement Kawasaki KLR 650

How to Replace Kawasaki KLR650 Clutch Cable

Step 1. Loosen the nuts locking the clutch cable in place near the clutch arm to release all tension at the handlebar end.

Kawasaki KLR 650 clutch cable

Step 2. Remove the 10mm bolt from the top of the handguard and loosen the lower bolt.  

NOTE: You won’t need to remove it completely, just loosen it so the hand guard hangs there.

Step 3. Release the tension on the clutch adjuster at the handlebar.  Line up the channels so you can remove the cable and drop the end out of the lever.

Kawasaki KLR 650 clutch cable adjuster

Step 4. Remove the cable from the clutch arm.

Kawasaki KLR clutch cable change

Step 5. Use electrical tape to connect the bottom of the old cable to the top of the new clutch cable. Keep the diameter as thin as possible so it can travel through the motorcycle. Pull the old cable until the top end of the new cable reaches the lever. 

NOTE: You may need to feed the new cable up as you go.

Kawasaki motorcycle clutch cable replacement

Step 6. With the new cable in place, connect the lower end first.  Feed it through the bracket and connect it to the clutch arm. Tighten the nuts and slide the boot in place carefully.  

Kawasaki KLR650 motorcycle clutch cable change

Step 7. Reconnect the end to the lever and slide the cable into the adjuster. Screw the adjuster out to tighten the slack in the cable. Don’t over-adjust it so the clutch can’t fully disengage. Keep a little slack at the end of the pull.

Does your Kawasaki bike need a new clutch? Watch the video above to learn how to replace the clutch on a Kawasaki KLR 650

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