Clutch Adjustment Question

[lissard]

Installed a new clutch cable and adjusted the clutch and cable per instructions in Clymer manual and the clutch does not seem to be (not sure I have the correct term here) ?engaging?. Bike would not start, acted like low battery (fully charged) turning over slowly. Accidentally bumped it into first gear getting off and when I tried to start again in 1st  with the clutch lever pulled in, the bike lurched forward like it was in gear without the clutch in. I assume either the adjustment is incorrect or the clutch is shot. Are the adjustment instructions in the Clymer manual correct? Summary of instructions below:

1. Remove access cover, loosen locknut, turn adjustment screw out 2-3 turns.
2. Turn adjustment screw in until it becomes difficult (with mine it went very suddenly and dramatically from very easy to very tight/difficult) and back off 1/4 to 1/2 turn.
3. Adjust cable at lever to provide 4mm free play at "break location" (where lever moves away from pivot/mount).

Anybody have similar experience or ideas as to what is going on?

[scratch]

Did you loosen the adjuster on top of the crankcase?

Loosen the adjuster at the lever, loosen the adjuster on top of the crankcase, and then loosen the screw underneath the access cover.

The screw underneath the access cover, I usually loosen the nut, unseat, or back, the screw off so it's not contacting anything, then screw it in slowly until it lightly contacts. Tighten the locknut so that it does not tighten the screw any further. Tighten the adjuster on the crankcase next so that there is 4mm of play at the lever (I typically adjust it so that there is 3mm of play at it's tightest point, usually with the handlebars at full-lock left). Then make the fine adjustment at the lever, if any.

[lissard]

I loosened the adjuster at the crankcase, but I guess its possible it may not have been enough. I'm gonna try and look at it some more tomorrow.

Anybody know if the adjusting screw under the access cover should tighten gradually or suddenly?

[Kerry]

Anybody know if the adjusting screw under the access cover should tighten gradually or suddenly?

You mean like "How big of a change per turn of the screw?"  It's fairly gradual.

[scratch]

Just seat the screw. Do not back it off. Because of the gradual tightening (fine threads), if you back it off you're adding additional space requiring the actuator to lever it in more, and it doesn't reach far enough to part the clutch plates. Thus you're still getting the clutch 'drag'.

[lissard]

Hey, thanks for the input. I've been down and out with lower back problems for the last couple of weeks. When I did the adjustment it didn't seem to tighten gradually just kind of locked up within about 1/4 of a turn. I'll have to retry making sure I have enough play at the adjuster at the top of the crankcase. I also won't back off once I adjust the clutch per Scratch's advice. Thanks again. I'll probably try it tomorrow night. Got dragged into something for tonight.