Adjusting the clutch cable

[Nomak]

The bike sometimes grinds in the lower gears. It also gets stuck in neutral sometimes. It seems that there is too much slack in the clutch cable. How can I rectify this problem?

Thanks

[JeffD]

Take off the boot over your clucth lever.  There should be an adjusment knob.  Adjust it until its where you want it.

[Kerry]

1) Unseat the rubber cover and push it down the clutch cable to expose the adjusting hardware.  This is usually the hardest part for me....
2) Loosen the large split ring (spin it away from the handlebar).
3) Screw the adjuster in toward the grip to increase freeplay, away from the grip to decrease freeplay.
4) Check the clutch lever freeplay.  Spec is 10-15mm at the ball end of the lever.
5) Repeat steps 4 and 5 as needed.
6) Retighten the ring against the clutch lever housing.  Use no tools, but get it as tight as you can with your (gloved) hand.
7) Replace the rubber cover.  (Much easier than getting it off!)

EDIT: Changed link from sisna.com to bbburma.net.

[Turkina]

Will lubricating the clutch lever lessen the force you need to squeeze the lever?  And how would you suggest on doing it?    I always seem to see some little device used for lubricating the things.  If it makes my hand hurt less after going through traffic...

[Kerry]

Will lubricating the clutch lever lessen the force you need to squeeze the lever?

It certainly can, but there's no guarantee.  If the clutch is VERY hard to pull the cable may be getting ready to snap.  (Been there, done that!  That was before I saw the wisdom in lubing my cables.)

And how would you suggest on doing it?    I always seem to see some little device used for lubricating the things.

I use a device like you describe, which came with my can of Cable Life.  It took a couple tries before I figured out how to attach it right - so it wouldn't spray everywhere.  But once you figure it out, it's quick!

For a low-tech method, see item 1 in my post in the old thread tight clutch cable.

[MarkusN]

If the adjuster nipple on the Handle does not give you enough travel, there's a second nipple at the other end of the cable (Entering the motor case on the left side)

Again:

clear away sleeve
loosen locknut
adjust nipple
tighten locknut
reset sleeve

This position gives you much more adjustment travel.

[Kerry]

Great follow-up Mark!  You inspired me to go out and take a new photo for "the collection":



Thanks for the reminder!

EDIT: Changed link from sisna.com to bbburma.net.

[Manix]

And if you choose to buy that Cable Life-thingy, you need to take the clutch cable off from the handle. To do this you may have to loosen the cable from the engine side too.

I have a similar contraption to Cable Life myself and lemme tell you, it did wonders for my throttle cable. It wasn't bad to begin with but when I lubed it properly, it did wonders. Somehow the bike seems to accelerate more quickly (might be just in my head).