Question about 2004 Yamaha YZF-R1

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How do i take the slack out of my clutch cable after i replace the clutch

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Turn clockwise the tensioner on your left lever all the way in.Loosen up the 2 nuts on the clutch cable's bottom end.Pull the **** (not especially hard though) and tight the nuts back.Then go to your lever's tensioner bolt and adjust the cable so that the lever's end (ball) should move 2-3cm before the cable stretches (freeplay 20-30mm)

Posted on Feb 10, 2012


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Posted on Jan 02, 2017

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SOURCE: stiff shifting into second gear

Yes, too much slack can cause the problem. Remove the slack by adjusting the cable at both ends if needed. Here's the deal, if the clutch does not work fully, the engine is still applying pressure to the driven gear. The pressure on the gear does not let the shifter move freely.
Try this little test > on a clear road shift from 2nd to 3rd using the clutch but don't let off the gas when you shift. If the motor reved up when you shifted then the clutch was doing its' part at least a bit. Now do the same process but this time do not use the clutch at all. Instead, let off the gas when you shift. Letting off the gas lessens the drive pressure on the gears and will allow the shifter to better do its' part. Not using the clutch is commonly referred to a "power shifting ". If out on the road and the clutch cable breaks, this is a way to keep going for a bit.
As to worn dogs and shift forks, your bike is pretty new so I doubt wear is a problem. A bent shift fork is a possibility but since you have a funky clutch cable I suggest we keep it simple and start there.

Posted on Mar 17, 2009

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SOURCE: clutch cable

first need to set push rod freeplay 1/16th clearance @ engine clutch basket then set handle bar 41dee43.jpg

Posted on Mar 31, 2009

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I have a tsr 250 bigboy clutch cable broke, which i replaced now i have no gears even if it is fully adjusted any advise that might help

Hi, Daniel give the cable tons of slack then adjust the clutch pack center screw (if you have one) until it just barely touches then take up the slack in the cable until you have 1/8" free play at the lever or for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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Clutchbitting close to the floor

Is this a hydraulic or cable operated clutch?

If hydraulic, then replace the clutch disk.

If cable, then try adjusting the cable to take away some slack. If already adjusted, then replace clutch disk.

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How do I adjust the clutch cable on my Harley softail

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Clutch is slipping on my 2008 flhx how do [ adjust clutch beyond adjustment in cable

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1 Answer

I just replaced my clutch cable, but now that I've put everything back together I have a problem. The bike will from neutral to first and back without the clutch lever pulled in. However it also...

Good news, you just need adjust the clutch cable..

Always order the part for your model and year when getting parts and make sure it matches in length with the old one. Note how much cable is sticking out of the housing.
Is it 3 1/2 inches or 4 inches or 2 inches. make sure the new one matches.

Put the new cable on with lots of slack.Slack at the adjuster, and slack at the handlebar adjuster
Now pull the lever in, it will be easy because of the slack.let it stay there.
It will stay against the grip.
As you tighten the cable adjustment down by the cover, you'll notice the clutch lever move out.
Once it reaches the top, stop adjusting and pull it in again.
Continue adjusting and pulling the lever until the lever springs back to the top.
You can feel resistence which is the clutches disengaging.
Make sure there is 1/8" free play when the lever springs back.
Now turn the clutch cable adjust on the handlebar outward, which will remove the rest of the slack.
Only leave 2mm slack on the lever.

Now start your bike up and it should work like new.
You want your clutch to disengage within the first 1/2" of pulling the lever in.
This ensures the clutches are definately disengaged by the time you get the lever pulled back to the grip when shifting.

If your clutches are slipping or dragging no matter how you adjust the cable then your clutches may need replaced.
But sounds to me like its just an adjustment.
Hope to be helpful
Big Al

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1 Answer

Hi , how slack should the cable be on my raptor 660 clutch ,it's a2003 model

All clutch cables need about 1/4" slack at the handle bar. This is so the thrust rod is not constantly rubbing on the clutch thrust plate.

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1 Answer

Trying to adj the clutch on a 2004 sportster can you tell me how to do this please

Slide the rubber boot away from the clutch cable adjuster. Loosen the lock nut and turn the adjuster inward to provide as much slack in the cable as possible.

Remove the clutch inspection cover. Remove the spring and the locknut at the adjuster. Now, turn the adjuster bolt counterclockwise until it stops. Then turn it back clockwise 1/4 turn. Replace the locknut, spring and the inspection cover.

Now adjust the clutch cable adjuster outwards until you have almost no slack in the cable. Work the clutch a few times and then adjust the cable so that you have between 1/16" and 1/8" freeplay at the hand lever.

Good Luck

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is there any slack in the cable, i mean can you pull the clutch lever in just a bit with no tension? im not certain with that bike, but there my be a internal adjustment that may help. if not then its likely you need to replace the clutch plates. hope this helps..

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2005 FLHTCI Clutch Adjustment

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