My clutch does not grab at the same place every time.
Some times it begins to engage when the lever is only about 1/3 released. Other times it woun't start engaging until it is 3/4 released.
What is really annoying is when it starts engaging at 3/4 released and I pull the clutch lever back in a little, it will suddenly grab and the bike will lunge foward.
Any thoughts on whats causing this would be appreciated.
The bikes a 2009 KLX250s with 3,300 miles.
Thanks,
Craig

 

Hows your oil?

 

Have you checked the clutch lever cable thoroughly? Make sure it's not kinked or the housing is broken somewhere?

 

Dirty oil was my first thought as well. Does the engagement get change after it is ridden for a bit. If your cable does not have enough play it can cause the clutch to not fully disengage causing minor slipping and heat up the plates. A hot clutch does weird things at the lever.

 

I should have mentioned that I changed the oil at 3,000 miles, but it did not solve the problem.
I also lubed the cable.
I will check for kinks or frays and report back.
Craig

 

is your clutch cable adjusted correctly ? how much free play ?

 

It turns out the clutch cable was riding on top of my aftermarket handguard clamp. When the steering was turned all the way to the left the cable jacket would pull out of the detent on the adjuster. The sudden clutch engagements must have been the cable end jumping back in.
I ground down and rounded the edges of the clamp and lenghtend the cable a bit by using the adjuster in the cable that runs along the frame down tube.
It has been raining all day here, so I haven't taken the bike out yet, but by turning the steering side to side now, the cable end seems to be staying in place.
Thanks for all your help.
Craig