Motorcycle Repair: clutch, clutch mechanism, clutch cable

Question
Hi Cris, thanks for fast reply,

I read my manual and unfortunatelly they don't give any details about clutch exept from regulation of clutch cable. And this instruction is also insufficient for me, they only mention that I should adjust it to have 4mm of loose or something like this, they dont say how to recognise that there is that 4mm, what are the symptoms etc.

I thing the clutch mechanism is still ok and i didnt break anything, but I still have to adjust the lenght of a clutch line properly, so please tell me how you do it and how to recognise that this is the proper lenght.
I mean that when you turn the bolds of clutch line there must be some signs that now it is too loose or to short. Meybe you each time try to ride to asses if it is ok or not? And another thing, I dont know if the engine should be warm or cold when regulating it? I dont even know if my clutch is dry or immensed in oil...

thanks a lot,

kasia  

Answer
Hi Kasia.
 To start with, you have what is called a "wet sump" clutch.  That means that the oil used by the engine is also the oil used in the clutch.  They share the oil between them.  Even your manual should say that in the general information section or the clutch and transmission section.

 As far as the adjustment, if your manual doesn't show and tell you how to make the adjustment then you are not looking in the REPAIR manual.  The owner's manual is pretty useless for repairs and adjustments.  If you have a repair manual that does not have that information, then go to a dealership and order the correct one which will have all of that information; but I have never seena repair manual that did not have all of that info in it.

 To adjust the clutch cable correctly, you must have the specified amount of FREE PLAY.  That means that you adjust it so that the clutch does not engage until it has travelled the specified distance.  Most bikes require 1/4 inch of free play, but your bike requires 4mm (which is likely the same once you convert from standard to metric).  To do that, you loosen the adjuster lockdown knob on the lever (the big one that goes around the cable adjuster), then you turn the adjuster (the small one that the cable seats into) and turn it (in or out depending on if it's too tight or loose) until the lever travel is 4mm before the clutch begins to engage (when you feel tension on it).  At that point, you tighten down the lockdown knob and the clutch should be fine.

Now some bikes have an additional adjustment at the engine side of the cable as well.  That may need to be adjusted first, so refer to your repair manual for that, since it varies on each bike.  If you have one, it will be pretty obvious as it will be another, smaller adjuster where the cable enters the engine or connects to an actuating lever on the engine at the clutch location.

Good luck.
FALCON