Question about 2004 Bajaj Caliber 115

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While i releasing the clutch skipping the chain

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  • Edward Hurst May 11, 2010

    Need to know more. How much slack do you have in the chain? If the chain is fairly tight (within specs) it could be that you have some teeth on the sprocket that are severely worn. If the chain is to loose it should be tightened up and try it again. If the chain is not jumping teeth, I would look for the damper in the rear wheel slipping. It has rubber pads, for lack of a better term, in the rear hub that can slip if there is extreme wear. The damper is there to take out the harshness of the gear change.


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From your very brief description I am guessing the drive chain is jumping over the sprocket on the rear wheel?
If this is so then you maybe a little late for rectification and the drive sprocket may be worn out?
If on inspection of the Cog/Sprocket (Where the chain goes round) The teeth are sitll very deep and NOT hooked or worn then you may be able to stop it jumping by adjusting the slack in the chain.
You need to do this regulary as although the chain is made of Steel it still stretches over time and varying loads/conditions.
Refer to your owners manual on how to do this as it is essential adjustment is done correctly.
You need to loosen the wheel mounting i.e. spindle and adjust by means of screwing in the 10mm nuts on the clamps situated either side of the swing arm/frame. They must be done equally on either side as wheel will be out of true!
If you are unsure about this then take it to your local Motorcycle dealer/repairer and he or She will adjust/replace as necessary the drive chain and sprocket for a fee.
Good luck and remember maintenance on a regular basis can save money in the long run.
Paul 'W'
Onyer~EDson(:0)~[>< U.K.

Posted on Jan 10, 2009

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3rd gear slightly skipping what should I do?

Tighten the clutch line, check for wear on the third gear and chain, tighten your chain to proper specs for the bike.

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Clutch won't release

Hi Anonymous, and the usual suspects are:
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Noise in primary when releasing the clutch sounds like chain slapping

It could be the primary chain slapping. When is the last time it was adjusted? Take the inspection cover off that's in the center of the primary cover. Reach in with your finger and lift the top run of the primary chain. It should be between 3/4" and 7/8" up and down slack in the chain with the engine cold. If it's too loose, loosen the nut on the adjuster just inside the inspection cover opening and raise the shoe to tighten the chain. Retighten the nut once you get it set correctly. If that's not the problem, it could be that the clutch discs are glazed. This is rare on the newer model bikes but I have seen it on a few occasions. The clutch disc will need to be taken out and cleaned and sandpaper used to slightly scuff the surface of the fiber discs. Try adjusting the chain first.

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If the bike starts when it is in gear that would indicate that the clutch switch is sticking/broken? It is located between the clutch lever and the clutch lever assembly, normally a plastic bullet shaped switch with a switch that is depressed when the clutch lever is not engaged and released when the clutch lever is pulled in. The not shifting could be down to the chain not adjusted for freeplay correctly, also lub the gear change shaft. If the chain is adjusted then check freeplay on the clutch lever normally about 10mm, but check with your handbook.

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I am reassembling the clutch cable, is there an online manuel for this job or bike

I'm afraid there is no online manual available. Harley is very protective of their copyrighted material.

If you've already gotten the outer primary off the bike and the old cable out. Insert the primary end of the cable into the primary cover and screw the adjuster with the lock nut on it all the way into the outer primary. Reconnect the cable to the release mechanism with the link.

Replace the outer primary but starting the screw for the clutch release into the nut in the release mechanism. Turn the screw counterclockwise while you put the cover back on. Do not forget the gasket. Once you get the cover in position, replace all the bolts in the cover an tighten them. Adjust the primary chain by removing the top plug and checking the slack with your finger. Adjust the primary chain adjuster on the underside of the primary until you 1/2" to 5/8" up and down play in the chain. Finish the assembly of anything at the primary, shifter, foot pegs, etc. Refill the primary with one quart of oil.

Connect the cable at the clutch lever. Back down at the clutch release mechanism, make sure you have the screw turned all the way counterclockwise until it stops. Then turn the screw back 1/4 turn. Adjust the cable adjuster at the front of the primary cover out until you have about 1/8 inch of freeplay at the lever. Lock the lock nut and replace the cover over the clutch release mechanism.

If you need a drawing, contact me directly at I'll send you one directly.

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How to adjust primary chain and clutch on 04 1200c thanks

First, let's adjust the primary chain first. Remove the upper inspection hole cover. Stick your finger in the hole, find the chain, and raise and lower it. With the engine cold, the chain should have 3/8" to 1/2" up and down movement. To adjust this, look underneath the primary. You'll see a bolt and a lock nut. under the primary. Loosen the lock nut and turn the adjuster to adjust the tension in the chain. Adjusting the bolt upwards tightens the chain, lowering it loosens the chain. If you get the chain too tight, lower the chain until you get too much movement in it and then raise the adjuster again.

On the clutch, remove the clutch release mechanism cover. Remove the spring and the lock nut. Find the cable adjuster in the middle of the clutch cable. Move the cover up or down, break the lock nut, and adjust the cable adjuster inwards until you get a lot of slack in the cable. Turn the adjuster bolt at the relaese mechanism counterclockwise until it stops. Then turn it back clockwise 1/2 turn. Install the locknut and spring and cover. Go back and adjust the cable adjuster outwards until you have about an 1/8" freeplay. Lock the lock nut and replace the cover.

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Dec 19, 2010 | 2004 Harley Davidson XL 1200 C Sportster...

1 Answer

I have a 2002 xv 250 and when i shift into first i can feel the clutch grab slightly i tried to adjust the clutch lever but that did not work also chain seems to be making excessive noise while riding

From what you are describing it sounds to me like your drive chain needs adjusting & lubricating regarding the clutch how longs it been since your last oil change & service if its over due the oil may have become sticky & your clutch plates are not releaseing drain the oil remove the old filter fit a new one & add fresh oil this should go a long way to remedying your problem

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Synchronize the carburetors. Carburetors that are out of synchronization will cause the clutch and primary chain to rattle.

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What kind of parts are insde the chain sprket cover where the cluth line enters the case . My cluth line is tight not engageing. I looked at pictures on the ent apartently im missing like a a piece of...

This is inside the casing cover. Just a lever for the clutch cable to connect to, a spring, The clutch release mechanism, a seal and a clutch push rod. The clutch release has a threaded screw for adjusting the clutch and a locking nut for the screw. The only other thing is a metal bracket.

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