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Clutch Adjustment (Read 42 times)
SoC
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Clutch Adjustment
05/20/20 at 19:55:14
 
Hey Folks, would appreciate some guidance on doing some clutch adjustment. I'm sure there has been plenty of posting on it in past, I just am having trouble locating it. It all started when I installed a Versy cam chain tensioner and obviously had to disconnect cable to pull side cover. Thought I had marked it on disassembly, but have been having some slippage since I put it all back together. It is obvious on hard pulls when excelerating. I tried to do a readjust last week, initial ride it seemed good, but today on highway it was slipping a bit when ramped up on the rpms. It seems fine when slowly excelerating. Is there a tutorial on doing adjust?
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justin_o_guy2
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Re: Clutch Adjustment
Reply #1 - 05/20/20 at 20:21:59
 
Your clutch lever needs to have a bit of free play before the cable comes tight.
If you used some fancy oil with friction modifiers, that is the problem
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philthymike
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Re: Clutch Adjustment
Reply #2 - 05/20/20 at 20:24:14
 
I adjusted mine over the weekend but only needed to do the lever adjustment. I loosened the locknut on the adjuster and then turned the adjuster all the way in to the lever mount. Then used a 4mm allen wrench for measuring the free play of the lever. As I backed the adjuster out I kept comparing the gap between the lever and it's mount at the outer edge to the thickness of the wrench. Once the gap was slightly less than the 4mm wrench I tested the clutch operation. It felt great. I left it there and tightened the lock nut.
I have a good range of actuation, about 2/3rds of the lever travel. No slipping. No creeping.

The adjuster on the clutch side is the same process but I didn't need to do it and don't know the measurements.
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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE
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Keifer
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Re: Clutch Adjustment
Reply #3 - 07/07/20 at 15:47:19
 
I also need to adjust my clutch.  There seems to be no 'freeplay' at the lever, it pulls on the case arm instantly.  So I'll adjust that...
But when I pull in the clutch lever and shift into first, the bike dies (or grinds).  So it clearly isn't disengaging the clutch fully.  Can the disengagement be adjusted or is that just the sign of a stretched cable?
(This bike hasn't been on the road yet)
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93 Savage - 21K miles
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