Question about 1984 Yamaha XJ 600

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Gear change whats the best way to adjust the clutch cable and lever it slams into 1and 2 gear

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Hi,this is quite a common problem on these,before you put it into gear pull the lever in two or three times,this will loosen up the clutch plates a little,if i am right it normally only happens when the bike is cold?,the cause is the oil in the gearbox(wet clutch)is probably a little bit heavy,this is why bikes use a multigrade/friction modified oil,hope this helps...cheers

Posted on May 03, 2010

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HOW CAN I TELL IF I ADJUSTED MY CLUTCH CORRECTLY ON 2005 HARLEY SPORTSTER


Hi John, the correct clutch adjustment procedure is as follows: Loosen the jam nut on the clutch cable adjuster and screw the adjuster in about 1/2 " this should give you tons of free play at the clutch lever. Remove the the left footrest, the clutch inspection cover and slide the spring and lockplate off of the adjusting screw. Turn adjusting screw counterclockwise untill resistance is felt then clockwise 1/4 turn replace lockplate and spring, check for proper fluid level in primary and button back up. Back out the clutch cable adjuster untill you get 1/16" to 1/8" freeplay while pulling the clutch lever with your left hand and the clutch cable in the oppisite driction with your right hand. Tighten jam nut and your good to go. Good luck

Mar 25, 2015 | 2005 Harley Davidson XL 883L Sportster

1 Answer

After a gear oil change how do i adjust the clutch


Because the clutch cable adjuster clearance increases with engine temperature, adjust
the clutch when the engine is cold. If the clutch is adjusted when the engine is hot, insufficient pushrod clearance can cause the clutch to slip.
1. Remove the clutch mechanism inspection cover and
quad ring
2. Remove the clamp and slide the rubber boot off the clutch in-line cable adjuster.
3. Loosen the adjuster locknut and turn the adjuster to provide maximum cable slack.
4. Make sure the clutch cable seats squarely in its perch at the handlebar.
5. At the clutch mechanism, loosen the clutch adjusting screw locknut and turn the adjusting screw clockwise until it is lightly seated.
6. Squeeze the clutch lever three times to verify the clutch balls are seated in the ramp release mechanism located behind the transmission side cover.
7. Back out the adjusting screw counterclockwise 1/2 to 1 turn. Then hold the adjusting screw and tighten the locknut to 72-120 in.-lb.(8-14 N•m).
8. Once again, squeeze the clutch lever to its maximum limit three times to set the clutch ball and ramp release mechanism.
9. Check the free play as follows:
a. At the in-line cable adjuster, turn the adjuster away from the locknut until slack is eliminated at the clutch hand lever.
b. Pull the clutch cable sheath away from the clutch lever, then turn the clutch cable adjuster to obtain the clearance gap
c. When the adjustment is correct, tighten the clutch in-line cable locknut and slide the rubber boot over the cable adjuster.
10. Install the clutch inspection cover quad ring onto the primary chain case cover.
11. Install the clutch inspection cover and tighten the screws to 84-108 in.-lb. (9.5-12 N•m).

Jul 12, 2014 | 2003 Harley Davidson XL 1200 C Sportster...

1 Answer

1st and 2nd gear keep jumping out of gear


You may want to make sure the clutch cable is properly adjusted. At the clutch lever on the handlebars, pull back the rubber cover over the end of the cable where it goes into the lever. You'll find a round lock wheel that you tighten to prevent the clutch cable adjustment from moving. Loosen that wheel then you can turn the clutch cable adjustment in or out to adjust the clutch engagement and take up. For those bikes, you want to adjust it so that there is a small amount of slack in the clutch lever. Look at the "crack" where the lever pivots when you pull on it. Adjust the clutch cable by turning that adjustment in or out until you have just barely enough opening to slip a nickel edge into the very outside of that "crack" when you apply very, very light pressure to the clutch lever (just enough pressure to take the slack out of the lever). Tighten the lock wheel back into place and try it now. Also, make sure you are using a good, FIRM foot pressure to engage each gear. If you don't engage firmly enough or the adjustment is out, then it will pop out of gear. You notice it more on the lower gears because the lower gears allow the engine to send more torque thru the clutch, thereby providing more force to make it pop out of gear.

If this doesn't help, then take it to a shop to see if it's simple worn clutch disks (easy to replace on this bike) or if the gears have worn teeth in the transmission.

Nov 05, 2013 | 1999 Yamaha V Star 1100 Custom

1 Answer

2010 Sportster shifts hard


Shifts hard,or bangs/slams in gear just means you need to take a bunch of play out of the clutch lever.Adjust the cable far enough that there is very little play in lever and the slam will go away.Clutch is dragging when you shift and won't allow gear alighnment smoothly,that's all.Need clutch fully open when shifting.

Sep 30, 2013 | Harley Davidson Motorcycles

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

Jul 25, 2011 | 1993 Yamaha FZR 600

1 Answer

The clutch is quit tight and the gear are not changing easily and not neutral.


well if the clutch cable is adjusted all the way in, then the clutch disc, and plates would need to be changed, especialy if its hard to shift in and out of gear while running. there should be two adjustments, a top lever adjuster, and a bottom lever adjuster. always adjust the clutch componets fron bottom to top.

Jan 06, 2011 | 2005 Honda Eterno

2 Answers

Dirt Bike Shifting gears problem(1972 yamaha dt 250 2stroke)


it will be down to adjustment, there are 2 ways to adjust one close to the engine casing and one at the lever just have to get a good balance :)

Apr 11, 2010 | 1972 Yamaha DT 360

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

2 Answers

Clutch wont dissengage


1) Can you push the bike while it's in gear with the clutch pulled in? [If so, clutch is disengaging OK]

2) If not, check when you pull in the clutch lever that it pulls all the way through to the actual clutch [If not, replace broken clutch cable]

3) If so, clutch is binding. Either fix it properly by stripping the clutch.. or just brute-force the plates apart. :-)

Brute-force clutch plate separation: First make sure you have enough oil in the engine (wet clutch), then basically you're looking at either riding it with the clutch lever pulled in until the plates come apart or with the rear wheel in the air CAREFULLY running it in first gear against the rear brake while the clutch is pulled in.

Mar 20, 2009 | 2003 Suzuki RM 125

1 Answer

LT 500 ATV clutch adjustment


Hi!
I havn't come across your Machine before but hopefully a little Q 'n' A will solve/FiXya problem.
O.K. 1st is the clutch cable operated? if so can the cable should be adjustable from the handle bars?(Then take up the slack to leave a slight gap when lever is pulled) Do this by loosening the locking screw on the end of the cable and turning the adjuster anti clockwise so tension is put on the cable Not the lever.
If the cable isn't adjustable from lever go down to the engine and do the same as above on the cable there.
2nd Is the clutch fluid operated (Master Cylinder on clutch lever) If so look for clutch pushrod and adjust it by loosening again the locking nut and winding it out to create less gap between pushrod and clutch arm. You may need to bleed the system if after adjusting still the same.(Come back to me on that if needed)
3rd If when carried out the clutch starts slipping i.e. in top gear Engine Rev's and doesn't move forward well? then release the tension on either cable/pushrod until happy medium.
Good Luck!
Paul 'W'

Jan 02, 2009 | 2000 Suzuki GS 500 E

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