I had my bike parked at work with the bars turned to the left and my co-worker pointed out that the top of the front fender in the rear half is scratched up. Upon inspection, it looks like it was caused by the metal aduster on the clutch cable rubbing it. Is this normal for this bike? I know there is almost no room for clearance but that seems like a bad design if it is...

 

I have not had any trouble like that. Can you post a pic, maybe the dealer put something in the wrong place when they assembled the bike.

 

After you posted this I had to go out into the garage and see if mine was rubbing. It isn't but it is really close, the cable actually goes through two hook/hangers, make sure they are both around the cable.

deej

 

Mines fine

 

I took it to the dealer and he adjusted the brackets a little so it would not rub. It must have been installed just a smidgen off at the factory. Like Deej said, it is very close there and the clearance is almost nil. Definitely not the greatest design. If you guys haven't checked it, it's worth the 10 seconds it takes to turn the handlebar full lock to lock and make sure it does not touch.

BTW, this has nothing to do with cables but while my dealer was adjusting the bracket, a guy on a shiny new Honda XL650L was asking me about my bike. I told him I liked my KLX a lot and also told him that I always liked the XL650L but with a seat height of 37 inches, was too tall for me at 5'8" 185lbs. As I was talking to him I noticed he wasn't that much taller than me and much slighter in build so I was pretty impressed that he was riding an XL. Anyway to make a long story short, the guy dropped his brand new XL right in the dealership parking lot backing it up on his tippy toes. We ran over to help him upright his bike. Man I felt bad for him.