Hello all,

I am currently near Temuco, Chile. My trip to Ushuaia was to begin today and now I find myself with a clutch cable that is on the verge of breaking.

I need to know what other models of motorcycles use the same clutch cable length so I can see if I can buy a replacement. I am thinking if any of the Honda, Suzuki or Yamaha assemblies use the same length cables. Kawasaki dealers and parts are hard to find around here.

If anyone from the area can help, I'd be very grateful too.

Actually every motorcyle dealer and possibly even lawnmower dealer should be able to help you. You just need cable and a couple of cable nipples, whether with a screw or for soldering. I would estimate that 80% of all motorcycle overlanders carry such a repair set, so may be you find someone else riding.

Kawasaki dealer apparently in Temuco:
http://www.motomaster.cl/contacto.htm
Casa Matriz Avenida Caupolicán # 380 Fono: 45 - 401640 Motorrad.
motomaster@surnet.cl

Sucursal Avenida Caupolicán # 489 Fono: 45 - 211208 Kawasaki
ventas@motomaster.cl

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I've had more issues with clutch cables on my KLR than with any other repair. The original cable lasted almost forever (±50k miles/80k km) but after that I had some which went just a few thousand miles, others which lasted 10k or 20k. They all looked the same at first.

The first thing you need to know is that cables can be fabricated as Keks states above: they'll use your existing cable ends and attach them to new cables. Second thing is to always carry a spare cable zip-tied to the one in use--ends sealed so it doesn't corrode out. That makes installing the new cable (in the dark and rain, generally) fast and easy. I had so many troubles I took to carrying a third cable in my baggage.

I found OEM Kawasaki cables long-lived, at least if purchased in the States. The ones I purchased along the way varied astoundingly, but a reliable local source will know where to buy a good one (and I'd suggest buying two while you're at it). Then, watch like a hawk for the fraying which warns of imminent failure.

The last thing it's important to know is that you can ride without a clutch. In fact, it's worth trying this out just to develop confidence; just shift up or down without clutching while moving. Starting off is awkward, since you need to get moving while in neutral, then jam the bike into gear; always stop on a hill, or someplace where you'll have help pushing. I made it across Paso de San Francisco clutch-free by stopping only on hills....except at the Argentina border station, which is located in a little dip. The border guards, who'd been less-than-friendly, got a huge kick out of push-starting me.

Hope that's helpful.

Mark

I ended up having a new one fabricated from another bike's cable, soldering my nipple onto this new one. Works great, though I don't know how long it will last.

I will stop by tomorrow at the place mentioned by Keks. I called them and they don't have the part but were willing to take a look at the cable for me. Will do it tomorrow.

Thank you all for your help.

Welp, ****. Solder joint broke after 150 km. Still in Temuco looking for a better welder or new cable. Kawasaki dealer has no cables in stock. I am a bit worried to ride into Patagonia on a welded cable if I can´t bring a welder with me.

It's not my business to tell you what to do. However, if it was me I'd make a point of doing whatever it takes to carry at least one, possibly two new spares--see my description in an earlier post. You failed to carry a spare earlier, which is why you're in the situation you're in. Now it's time to learn the obvious lesson and ensure it doesn't happen again.

"In stock" is not generally a problem in Chile, since infrastructure is good and parts can be overnighted or put on express buses to get them to wherever you're at. More than likely, that will mean waiting around for a few days and paying the shipping fees. That's not a bad deal for you considering the consequences of parts failure in a more remote place--you'll still have the issue of waiting around and paying for shipping, but from an even more awkward base. Two days downtime is not a big deal in the context of a long trip.

Or you could have another roadside repair done and hope for the best. Usually they'll last longer than 140 km, but not always.

Hope that's helpful.

Mark

Sounds like you are in a dilly of a pickle.

A lot of moto shops sell universal, adjustable clutch cables (just the cable, not the assembly) in Latin America. Basically you cut the existing cable, remove it, then insert the adjustable cable in the clutch cable assembly. One of the nipples locks into place via a small screw. Cut off the excess cable. You must constantly adjust/tighten it though.

Another option is to use a pair of vice grips as a lever. Fasten them to the clutch arm and engage the clutch with your leg. You could also use the vice grips as a clutch lever if the original clutch lever or cable breaks at the top.

Suerte, and be thankful you are in a Chilean city and not in the altiplano...

You should be able to find a cable in the larger cities. I know the dealer in La Serena was well stocked for KLR parts. Certainly no problem in Santiago.
You see quite a few KLR's around Chile.
I'd try calling Conception or Talca. I had some very competent service done in Talca and saw a couple of other KLR's around town.

BTW I carry two spare clutch cables for mine and still haven't had one break, go figure!
Sorry I'm not nearby to help.