Join Date: Mar 2008
Location: Kapuskasing Ontario Canada
Mentioned: 10 Post(s)
You just need to take up the slack at middle of clutch cable. The adjuster on the back of valve cover, beside throttle cam.
•Pull the clutch lever just enough to take up the free play
•Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it.
Clutch Lever Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment.
•Turn the adjuster (at hand lever) so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) of threads are visible.
•Open the clamp (securing middle of clutch cable to engine).
•Slide the dust cover at the middle of the clutch cable out of place.
•Loosen the locknut at the middle of clutch cable.
•Turn the adjusting nut until the free play is correct.
Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or it could slip into place later, creating enough cable play to prevent clutch disengagement (possible explanation to your scenario).
•After the adjustment, tighten the locknut and start the engine and check that the clutch does not slip and that it releases properly.
Last edited by invader; 10-02-2012 at 08:09 AM.