Clutch Lever and Cable (KLX110D)
Due to friction plate wear and clutch cable stretch over
a long period of use, the clutch must be adjusted in accor-
dance with the Periodic Maintenance Chart.
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust pipe
during clutch adjustment.
Clutch Lever Free Play Inspection
Refer to the Clutch Lever Free Play Inspection in the Pe-
riodic Maintenance chapter.
Clutch Lever Free Play Adjustment
Refer to the Clutch Lever Free Play Adjustment in the
Periodic Maintenance chapter.
Clutch Cable Removal
Tuck the rubber boot [A].
Loosen the locknut [B] and screw in the adjuster [C].
Align the slots [D] in the clutch lever, locknut and adjuster,
and then free the cable from the lever.
Loosen the adjusting nuts [A] fully.
Free the clutch inner cable tip [B] from the clutch release
lever [C], and free the clutch cable from the clutch cable
Pull the clutch cable out of the frame.
Clutch Cable Installation
Installation is the reverse of removal.
Run the clutch cable correctly (see Cable, Wire, and Hose
Routing section in the Appendix chapter).
Adjust the clutch lever free play (see Clutch Lever Free
Play Adjustment in the Periodic Maintenance chapter).
Clutch Cable Lubrication and Inspection
Whenever the cable is removed, or in accordance with
the Periodic Maintenance Chart, lubricate the clutch ca-
ble (see General Lubrication in the Periodic Maintenance
Apply a thin coat of grease to the cable ends.
Use the pressure cable lubber to lubricate the cable.
With the cable disconnected at both ends, the cable
should move freely in the cable housing.