2.10 Check And Adjust Clutch

CHECK AND ADJUST CLUTCH                                                                                                           2.10

CHECK AND ADJUST                                                         8.   Tighten adjuster lock and recheck clutch specification.
                                                                              Refer to Table 2-10.
                              NOTICE
                                                                         9.   Reinstall boot.
The clutch control cable must be oiled and adjusted
periodically to compensate for lining wear. Failure to oil               Clutch cable adjustment when replacing clutch cable or
and adjust the clutch control cable can result in equipment              lnline adjuster has been moved:
damage. (00203c)
                                                                         1.   Engine should be cold.
                            NOTE
Perform maintenance more frequently in severe riding                     2.   Rotate front wheel straight ahead.
conditions. This includes extreme temperatures, dusty
environments, mountainous or rough roads, long storage
                                                                         3.   See Figure 2-16. Slide clutch boot (1) back.
conditions, short runs or heavy stop/go traffic.

                                                                         4.   Operate clutch lever (3) 3-4 times assuring cable is
 If the clutch slips under load or drags when released, the control
                                                                              properly seated.
cable may need to be adjusted or clutch service may need to
be performed. If clutch service is needed see CLUTCH
                                                                         5.   Loosen adjuster lock(4).
(Page 5-12).
                                                                                                    NOTE
The clutch lever should move smoothly through its full range.
                                                                         Do not turn the adjuster past the point where no gap is
Clutch cable at clutch lever check:                                      achieved, this could pre-lift the clutch.

1.    Check with engine cold.
                                                                         6.   Turn adjuster(2) clockwise until adjuster bottoms out.
2.    Rotate front wheel straight ahead.
                                                                         7.   Turn adjuster counterclockwise 3 full turns.
3.    See Figure 2-16. Slide clutch boot(1) back.
                                                                         8.   Tighten adjuster lock.
4.    Operate the clutch lever(3) 3-4 times.
                                                                         9.   See Figure 2-17. Remove inline adjuster (4) from cable
                                                                              holder(2).
5.    Check free play(5) specification. Refer to Table 2-10.
                                                                         10. Slide boot(1) back.
      a.    Pull clutch cable straight out from hand lever.

            Measure gap between adjuster(2) and the shoulder             11. Loosen adjuster lock(3).
      b.
            of the metal ferrule on the cable sheathing.
                                                                         12. Adjust inline adjuster until there is no gap in the clutch
                                                                             lever.
6.    If not within specification adjust clutch cable at clutch lever.

                                                                         13. Tighten inline adjuster lock.
Clutch cable adjustment at clutch lever:

1.    Engine should be cold.                                             14. Slide boot(1), covering clutch adjuster.

2.    Rotate front wheel straight ahead.                                 15. Place in cable holder.

3.    See Figure 2-16. Slide clutch boot (1) back.                       16. Perform Clutch cable adjustment at clutch lever in this
                                                                             procedure.
4.    Operate clutch lever (3) 3-4 times assuring cable is
      properly seated.                                                                   Table 2-10. Clutch Lever Gap
                                                                                MODEL                   MM                   IN
5.    Loosen adjuster lock(4).                                                 All Models              1.0-2.0          0.0394-0.0787
                            NOTE
 Do not turn the adjuster past the point where no gap is
 achieved, this could pre-lift the clutch.

 6.   Pull clutch cable straight out from hand lever, turn adjuster
      (2) counter-clockwise until it just makes contact with the
      shoulder of the metal ferrule on the cable sheathing.

 7.   Turn adjuster clockwise 2 full turns.

 2-18                                                                                                                         94000784
                                                  1559690

                                                            Boot
   1.   Boot                                                Cable holder
   2.   Adjuster                                            Adjuster lock
   3.   Clutch lever                                        Adjuster
   4.   Adjuster lock
   5.   Gap                                                   Figure 2-17. lnline Clutch Adjuster

           Figure 2-16. Clutch Lever Adjustment

94000784                                                                                            2-19