Question about 2002 Buell Firebolt XB9R

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Can't adjust end play out of clutch cable.need clutch teardown sheet.

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  • yadayada
    yadayada May 11, 2010

    get yourself a repair manual



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May I suggest a trip to your local library. Cycle repair books should be in 646 stacks of reference.

Posted on Oct 11, 2009


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How do I adjust a new clutch cable on a 2005 Yamaha v star 1100?

The normal method is once the cable is lubed and located at the engine and lever ends, the cable adjusters at both ends need to be adjusted to give the correct inner cable slack. I normally apply grease to the outer sheath metal crimps (this ensures they move in the adjusters). I then make sure the engine end adjuster has a small amount of clearance between it and the clutch rod. The final adjustments are then made using the cable adjusters at the lever and engine ends. You need to have about 10mm free play at the lever end. Check the manufacturers hand book for the exact dimension. Please make sure you route the cable the same as the old one, also when you pull in the lever it should close quite sharply when released. If it returns slowly or is stiff to operate then recheck cable route and try adding more lube to the inner cable.

Jan 15, 2015 | 2005 Yamaha V Star 1100 Classic

1 Answer

Clutch is slipping

The clutch friction plates may be worn out.

The clutch adjustment is likely way out in any case. You will need to go into the inspection (derby) cover and adjust the clutch and the cable adjustment will have to be done at the same time.

Slide the rubber cover off the cable adjuster. Then holding cable adjuster with a one half inch wrench, loosen the jam nut using a nine sixteenths inch wrench and back the jam nut away from the cable adjuster and then move the adjuster toward jam nut to introduce a large amount of free play at hand lever. THEN using a T27 TORX driver, remove the five TORX screws with washers to remove clutch inspection cover (derby cover) and seal in the primary cover (unless it has a gasket as aftermarket or Screaming Eagle covers will have in which case remove the gasket). IF the screws are very tight use a spring loaded impact driver with the correct T-27 TORX bit and a suitable sized hammer to shock them loose OR heat them with a hot air gun (sometimes people also put Loctite on the screw threads which then may need heat to break down this locking compound). THEN using an Allen key in, and to hold, the adjustment screw and a wrench on the locknut loosen the locknut and then turn the adjusting screw in or clockwise until resistance is felt (to take up all free play and lightly seat the adjuster to the clutch push rod but no more) and then activate the clutch lever to ensure that the clutch release balls are seated in the ramps. THEN back off the adjusting screw one half to one full turn. THEN holding the Allen key and adjusting screw so neither can move anymore tighten the locknut to 72-120 in-lbs (8.1-13.6 NM). THEN squeeze the clutch lever to maximum limit three times, to set the ball and ramp release mechanism. THEN replace the cover seal or gasket if it is very old, deteriorated or etc. and verify that the seal is fully seated in the groove of the cover and if there is a gasket make sure it is facing the correct way i.e. with the rubber sealing surface towards the primary cover and the triangulated screw hole to the top. THEN using the T-27 TORX driver, install the five TORX screws and washers to secure the clutch inspection cover in place and tighten the screws in a crosswise pattern to 84-108 in-lbs (9-12Nm). THEN move to the cable adjuster and turn the cable adjuster clockwise away from the jam nut until all of the slack is eliminated. THEN pull the clutch cable ferrule at the hand control end of the clutch cable at the hand control lever bracket away from the clutch hand lever bracket to check the free play. You need to obtain 1/16 to 1/8 inch free play between the end of the cable ferrule and the clutch hand lever bracket i.e. while you are pulling the cable away from the clutch lever mechanism bracket there should be a space or freeplay of 1/16 to 1/8 inch or in other words if you can pull the clutch cable away from the clutch lever bracket that much you have the correct lever free play, so turn the cable adjuster as necessary to get this amount of free play between the end of the clutch cable and the clutch lever bracket on the handlebars. After you have adjusted the cable so that you have this free play then hold the adjuster with a 1/2 inch wrench and using a 9/16 inch wrench, tighten jam nut against cable adjuster and then pull the rubber cable adjuster cover over the cable adjuster mechanism. THEN place the spring washer over the lower inside hole of the left footrest support with the concave side of the spring washer facing the support flange. These cable adjuster instructions are for stock HD clutch cables as aftermarket cables will be somewhat different to adjust BUT the idea will be the same.

May 25, 2014 | Harley Davidson FLSTC Heritage Softail...

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

1 Answer

1983 rm125 clutch

Adjust the cable tension with the adjusters fitted at either end of the cable. If you can't adjust the play out of the cable then you may need a new cable or a new clutch.

Feb 11, 2013 | Motorcycles

1 Answer

I have a 1999 suzuki marauder 800. Ive noticed that under load or heavy throtle that the clutch starts slipping. is there an adjustment i can make or do the clutches just need replaced all together. thanks...

as long as there is a little play on the clutch lever (1-2mm) then the clutch will probably need replacing. the cable can usually be adjusted at the lever end, and at the gearbox end, but given the age of the bike it is quite likely that the clutch need replacing. check for play on the cable first, but be prepared for a new clutch.
please feel free to ask again if you need fitting instructions.

Jul 15, 2011 | 1999 Suzuki VZ 800 Marauder

1 Answer

How do I tighten the tension on my clutch lever? My clutch isn't pulling at the lite.

Check your owners manual under maintenance for a description of how to adjust clutch lever "free play".

There is an adjusting knurled nut or adjusting nut (looks like a small sprocket) at the clutch lever... turning it clockwise will decrease the tension.. you probably need to turn it anti clockwise..Toward you as you sit on the bike to increase the tension.. remember there is only so much adjustment available... before you will need a new clutch.. Tinkering with this adjustment a few times in the driveway should help.. up to a point.

If you can't take up the slack this way.. you will have to loosen the lock nut at/near(the one at the end furthest from the termination point) to the the clutch and adjust (the adjusting nut is the one closest to the termination at the clutch) it at that end of the cable.. turn this adjusting nut toward the engine to decrease free play or tighten.. or away from the motor/anti clockwise to provide more free play) then readjust the lever end.. you basically want to remove the slop from a wearing clutch and stretched cable.

Nice bike.. enjoy.. ride safe

Best of luck

Apr 11, 2011 | 2007 Yamaha YZF-R1

1 Answer

I have a 2004 Honda VT750 Shadow Aero (shaft drive). Clutch apparently needs adjustment. Nuetral is easy to find but when shifting into 1st or 2nd or any other gear, bike stops. Is this a simple cable...

Adjustment is made at clutch end first and then fine-tuned at the handle bar end. Adjust at clutch end until there is no free play on the lever. Then slack off the nut a quarter turn. Test clutch operation and adjust at the lever end if nescessary. Remember to lock the nuts at the clutch end.

Feb 13, 2011 | Honda VT 750 Shadow Aero Motorcycles

1 Answer

I need to fit a clutch cable to my kawasaki z1b900 i need step by step instructions please

To remove the old cable first shorten the mid-cable adjuster to give as much free play as possible. If you need more free play screw in the adjuster at the clutch lever as much as possible and line up the slots so you can disconnect the cable from the clutch lever. Then remove the shift lever, and possibly the left footrest if needed to remove the front sprocket cover. Remove the cotter pin and disconnect the cable from the clutch release lever. Make a note of the routing of the old cable so you can replace it. Install the new cable with a new cotter pin at the lower end first, and route it the same as the old cable. To adjust the new cable, shorten the mid-cable adjuster as much as possible. At the clutch lever, turn the adjuster in and leave about 1/4" of threads showing between the locknut and the lever body. With the front sprocket cover still off, loosen the locknut on the clutch release lever and back the screw 3 or 4 turns. Turn the clutch adjusting screw in until it becomes hard to turn and then back it off 1/2 of a turn and tighten the locknut. Now lenghten the mid-cable adjuster until there is no free play and tighten the locknuts. Check that the lower end of the cable is fully seated in it's socket. At the clutch lever, turn the adjuster in so you have 1/16" free play, and tighten the locknut. Replace the front sproket cover and the shift lever and footrest.

Dec 23, 2009 | 1975 kawasaki Z1B

1 Answer

Clutch Cable Snapped

Hook the cable on the case lever then route the cable to the clutch handle. Turn the adjuster lock wheel all the way to the outer end of the adjuster then turn the adjuster all the way into the lever mount. This makes the adjuster as short as possible. Line up the cut-outs in the adjuster and the lock wheel to the cut-out in the lever mount. Hook the end of the inner cable into the clutch handle. Now pull the outer casing of the cable to the end of the adjuster. If the cable end isn't long enough to slide into the end of the adjuster then put the end of the outer cable on the adjuster shaft at the lock wheel and pull the clutch lever in. Now quickly release the lever while pulling the outer cable to the end of the adjuster. Normally it will pop into place so you can set the clutch lever 1/4" end play. You may need to try it a few times until you get it.

A “very helpful” rating for this answer? Thanks!

Jun 21, 2009 | 1981 kawasaki Csr 1000

1 Answer

Clutch bite is too far away from handlebar

There should be about 1/8" end play on the clutch handle. Adjust the cable at the handlebars where the cable goes into the clutch lever housing. Screw the adjuster inward until the end play is present. Some bikes have an adjuster at the gearbox where the cable hooks up.

May 05, 2009 | Hyosung RX 125 Motorcycles

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