Motorcycle Repair: clutch engagement adjustment, honda xl250, clutch lever

Question
Hi Chris,

I have a 1973 Honda XL250 and recently replaced the clutch plates.  I am having trouble adjusting the clutch so it engages in the middle of the lever pull.  I have adjusted the adjustment screw on the motor and at the lever but it continues to engage with the lever almost all the way out.  Any suggestions?  

Thank you in advance for your response.

Answer
Hi Kent.
 The clutch is supposed to engage near the beginning of the lever throw, not in the middle or at the end.

The reason that it is designed that way is because as the clutch is used, the cable stretches and the plates and springs begin to wear.  if the clutch lever actuated the clutch at the middle or end of the lever throw, then the clutch would, eventually, not be able to disengage and you, my friend, would be stuck somewhere fixing the clutch in the field, or worse; crash because you couldn't engage the clutch at a critical moment.

With the clutch engaging near the begining of the lever throw, you know early on, before a problem occurs, that the clutch cable needs readjustment.

Ride Safe.
FALCON