Question about 2003 CCM 604 DS Dual Sport

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Adjustment for the clatch

How much pressure or tension is correct for the adjustment screw on the sidecase of clutch?

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Hi I understood the correct adjustment for the clutch is as follows-slacken off the adjustment at the handle bars first then remove the plastic plug slacken the locknut and screw the screw in until contact is made then back off the screw 1/8 of a turn (what the ccm handbook says) the rotax engine manual says 3/4 of a turn but I think that is excessive. Then using the box spanner supplied in the ccm toolkit, carefully tighten the locknut ensuring the screw does not move with a screw driver. Re-adjust at the handlebar(2-3mm of slack). Also ensure there is the correct amount of oil, I checked mine cold after an oil change and I had way too much causing the clutch to drag when warming up. The clutch will tend to slip if the adjustment screw is in too far and there is no free play at the lever. Steve.,,,

Posted on Nov 10, 2008

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I replaced the oil cover and missed a step with my clutch now i dont have the right pressure or something when I squeeze my clutch help please

you have to adjust the clutch cable to ensure there is no slack in the inner cable so that the tension is restored?? Just like a car's clutch cable. The method of adjustment is what will take some working out .
The adjustment may include the correct positioning of the cable in brackets. adjustments at the ends or such like.
Sorry if that is not very specific but I work on cars and bicycles

Jun 25, 2015 | 2002 Honda VT 750 CD Shadow A.C.E. Deluxe

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Road king clutch wont' engage

Clutch discs worn out, pressure plate burned/worn out, diaphragm spring damaged or retaining screws loose or clutch adjustment or cable adjustment way out or basket/hub wear or release mechanism defective, bound up.

May 31, 2014 | 2000 Harley Davidson FLHR-FLHRI Road king

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Clutch not working?

About halfway down the clutch cable is an adjustment, covered by an accordian boot.

Slide the boot up out of the way, and at the adjuster, loosen the lock nut, and shorten the adjuster as short as possible.

Go back to the clutch pressure plate you seen under the primary cover.
In the center is an allen head screw with a lock nut around it.

Loosen the lock nut, and turn the allen head out about 1/2 - 3/4 turn.

Slowly turn it back in until you just feel it touch something. This is the adjustment screw touching the pushrod that moves the pressure plate out, to allow the clutch to release. Make sure the lock nut is unscrewed enough that it is not hitting the plate, causing the adjustment screw to feel like it stopped.

Again, with the adjustment screw JUST lightly touching, unscrew it 1/2 to 1 full turn.
Hole the screw from turning while you tighten the lock nut (about 20 ft/lbs torque, slightly more than spark plugs).

Now, go back to the cable adjuster, and unscrew it so the adjuster lengthens.
You want to adjust it so there is just a little free play at the clutch lever.
At the clutch lever, pull the cable away from it just enough to remove any free play. You're NOT trying to pull the cable off! LIGHTLY pull just to remove slack!

Proper adjustment is when the gap created by the above (between cable end and clutch lever cable holder/mount) is 1/16" - 1/8", go back and tighten cable adjustment lock nut, while holding the adjuster from turning.
3 wrenches help, 2 in one hand to hold the two adjuster hexes, and a 3rd one to tighten the lock nut.

Pull the clutch lever 3-5 times to insure the clutch release ramp balls are seated, and recheck the cable gap at the clutch lever.

If this doesn't work, the clutch plates probably got "welded" together (not literally, but a term used to indicate they are stuck together).

Then you'll have to tear the clutch pack apart to free up/inspect the plates.
A special clutch diaphram spring tool is needed for this.

Mar 01, 2014 | 2004 Suzuki RM 125

1 Answer

Adjust clutch on 2003 Yamaha V-Star 1100 Classic

Adjusting the Clutch Cable - Lower End
  1. Loosen the adjustment at the clutch lever
  2. Remove:
    - Left Side Cover
    - Clutch Adjusting Cover
  3. Loosen the locknut
  4. Turn the adjusting screw in until it is lightly seated - Be careful, the screw will keep turning with enough pressure. Just turn it in lightly until it stops
  5. Turn the adjusting screw out 1/4 of a turn
  6. Hold the adjusting screw in place, tighten locknut
  7. Replace covers
  8. Check the clutch cable free play and adjust (at the bar end) as necessary.
Adjusting the Clutch Cable - Upper End

Follow the procedure outlined in the Yamaha Owners Manual

Feb 21, 2013 | 2004 Yamaha V Star Classic

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I have a 2002 KTM 520 mxc. The bike started shifting hard as it warmed up. I replaced the clutch plates and springs with a Barnett digger kit. Bike shifts good now, but is slipping at higher RPMs.

The cable may be binding or the clutch adjustments may be wrong; there is normally two adjustments that have to be made if it is a cable style clutch.

1. the first adjustment will be on the engine near the clutch push rod and normally has a screw and locknut that is to be adjusted. Turn the handlebar adjustment first all the way in so that the cable has a lot of slack in it. Untighten the lock nut from the lower engine adjustment screw so that it does not interfere with the adjustment screw moving. Turn the screw inward until a very light tension is felt on the screw, then back it out about an 1/8 inch or so. tighten the lock nut back down and see if the locknut and screw together will rotate about 5-10 degrees when turned (this adjustment must not be so tight that it can not rotate when checked or it could cause clutch slipping so make sure that the adjustment screw rotates some after the locknut is tightened.

2. The final clutch adjustment is made at the handlebar. Turn the adjustment screw on the handlebar out until the clutch lever has about 1/8 inch of movement (before any tension is felt on the clutch lever) when the clutch lever is first being squeezed. Do not make the 2nd adjustment without any slack in the cable or the clutch may also slip.

If this is a hydraulic clutch and it slips at high rpm, the clutches could be getting hot, the springs are wrong for the clutch, or the clutch and steel fibers have the wrong installed height for the clutch hub (check the original clutch fibers and steels against the new ones installed and see that they are the same thickness or look up that fiber/steel thickness in a service manual).

Jul 23, 2012 | KTM MXC 520 Racing Motorcycles

1 Answer

Snapped and then replaced the clutch cable. Adjusted it all the way in and then slowly out trying to find the right spot to engage the gears. Have only been able to get 1st, N & 2nd gear. It will...

Hi Mark, a proper clutch adjustment for big twins starts by squirting some silicone spray or Brake Kleen into the top of the rubber boot on the clutch cable and sliding it upward exposing the cable adjuster. Loosen the jam nut and turn the adjusting screw in until light resistance is felt against the clutch rod then back the adjusting screw out 3/4 of a turn and tighten the jam nut. Check primary fluid level and replace derby cover. Go back to the clutch cable adjuster and back it out until there is 1/8" free play between the clutch lever and the bracket perch. This is correctly accomplished by pulling the clutch cable end outward with your right hand and pulling the clutch lever in with your left hand and modest pressure on both hands to eyeball the free play. Tighten cable adjuster jam nut and slide rubber boot back to it's original position. On Sportster models, the procedure is the same except the clutch cable adjuster screws directly into the primary cover with a jam nut. For more information about your issue, please visit the websites below. Good luck and have a nice day.
2004 Suzuki Motorcycle Service Repair Workshop Manuals
Suzuki VS 800 S50 Boulevard Clutch Change
Delboy Garage Harley Sportster Clutch Adjustment

Sep 28, 2010 | 2004 Suzuki VL 800 Volusia

1 Answer

Engine dies when bike is put in gear..... won't even roll when in neutral and engine off

If I recall correctly, the VStar engage/disengage point cannot be adjusted in terms of where in the range of the lever it is, something is not disengaged correctly. This typically indicates that there is too much freeplay . Reduce the freeplay just a tad and see if it resolves the problem.
clutch cables stretch with use and the adjustment at the clutch lever must be made on occasion. If there is no more adjustment at the lever, then follow the cable down and see if another adjustment is available. If not, you'll need to remove the cover to the clutch basket and find the adjustment there.
Now, just another thought. Bikes that have correct freeplay, but want to clunk and creep, may have sticky clutch plates/tension springs. This can happen when the oil is old or the bike has been sitting for longer intervals (previous owner?), or simply stuff accumulated and stuck to the plates. Not the most likely thing with your mileage, but don't completely rule it out.

Jan 18, 2010 | 2004 Yamaha V Star 1100 Silverado

1 Answer

CCM 604e to correctly adjust clutch cable, clutch drags

Turn the clutch adjustment bolt towards the clutch-lever surface all the way in-not too tight. Feel the lever pressure as crisp, engage the first gear, and see if the bike moves when you engage; stops when you dis-engage. Give the adjustment-bolt a couple outward turns, and see. Repeat procedure as necessary.

Nov 10, 2009 | 2001 CCM 604 DS Supermoto

1 Answer

Clutch Adjustment Issues / 78 Yamaha XS 650

Disconnect the clutch cable at the case then see if the there is any resistance in the clutch lever in-out movement. When the tank was remounted the cable may have gotten pinched or moved out of proper routing. If I understand correctly, prior to the frame painting the clutch was okay, but after the paint it was not, and the left and right side cases and clutch were not touched. Obviously you used the wrong brand of paint. The clutch would have been fine if you had used Krylon brand paint. Post a comment and let me know what you find.

Jun 24, 2009 | 1976 Yamaha XS 650 C

1 Answer

Cluch slips

I dont have a manual for that bike, but i think there is an internal clutch adjustment that may help. if not properly set, the clutch will slip under a heavy load. if it does have the adjustment, it will be on one side of the engine and it should look like a 10 or 12mm nut with a set screw. loosen the nut and adjust the set screw one way or the other until there is NO tension on the screw. tighten the nut and then re-adjust your clutch lever for proper free play. if that dont work, install high performace clutch plates. again, im not certain that bike has the internal adjustment. take a look. hope this helps...

May 27, 2009 | 1981 Yamaha XJ 650

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