Question about 1994 Suzuki VS 800 Intruder

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Have to play with clutch too get it too turn over

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My clutch on the handle bars dont stay primed

Posted on Sep 22, 2010


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Adjust a clutch on 2005 toyota echo

(a) Check that the pedal free play and push rod play are correct.
(1) Depress the pedal until clutch resistance begins to be felt.
Pedal free play:
5.0 to 15.0 mm (0.197 to 0.591 in.)
(2) Gently depress the pedal until the resistance begins to increase a little.
Push rod play at pedal top:
1.0 to 5.0 mm (0.039 to 0.197 in.)
(b) Adjust the pedal free play and push rod play.
(1) Loosen the lock nut and turn the push rod until the correct free play and push rod play are obtained.
(2) Tighten the lock nut.
Torque: 12 N*m (120 kgf*cm, 8.7 ft.*lbf)
(3) After adjusting the pedal free play, check the pedal height.

Mar 31, 2013 | 2000 Toyota ECHO

1 Answer

I cant get the clutch to engage

Hi assuming you put the clutch back togethere in correct order you remove it does the clutch lever have end play in it when you releace it there should be some play in it if there is not you need to loosen it ether at the lever holder or at the set screw where the cable on the engine case lossen it then turn it until it lighly stops then back it off quarter of a turn.

Aug 28, 2012 | 1992 Yamaha FZR 600

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

2 Answers

My rpm turns higher but my speed still remains the same.

Sounds like you have a slipping clutch. You can check your owners manual for the proper clutch lever free play. A quick check would be to see where you are starting to engage the clutch or friction zone. With the bike warmed up and running, shift into 1st gear and then start to slowly releash the clutch lever. If the clutch does not start to engage until the lever is 80% released, then you can try adjusting the clutch lever free play. You can do this simply by sliding the rubber cover from the clutch lever. If the cable end is showing a lot of threads then you can loosen the larger lock nut, a serrated looking wheel with a slot in it, and give the cable end a few turns in. Lock in the lock nut and start the bike and see if the friction zone is catching earlier. Try adjusting to get it to catch within the middle of the travel. Once you feel you have the clutch adjusted, give it a road test to see if the engine will not rev higher without a corresponding increase in motorcycle speed. The owners manual will give you a precise range where the clutch lever free play should fall, usually measured from the end of the clutch lever. If the clutch seems to be adjusted properly, then a worn out clutch could be the problem.

Good luck.

Mar 26, 2011 | Suzuki RG 150 Gamma Motorcycles

1 Answer

The clutch pedal on Suzuki vitara two litre V6 1998 goes to about inch of floor before activation. Clutch does not slip just too much pedal travel. Is it possible to adjust it? ...

prev.gif next.gif Clutch ADJUSTMENTS 1997-98 Models CLUTCH PEDAL HEIGHT The clutch pedal height should not be a periodic adjustment but may be checked after components of the mechanical clutch system have been replaced. The proper clutch pedal height should be 0.2 in. (5mm) above the brake pedal height If adjustment is necessary, loosen the locknut and turn the adjusting bolt until the appropriate height is reached. Once set, keep the bolt from turning and tighten the locknut to secure the adjustment. CLUTCH PEDAL FREE-PLAY The clutch pedal free-play should be checked from time-to-time in order to assure proper clutch operation. The proper clutch free-play should be 0.6-1.1 in. (15-25mm). Fig. 1: Pedal free-play is adjusted at the joint nut (2), while keeping the outer cable nuts (3) tightened around the center cable thread portion 7924hg30.gif
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. If the free-play must be adjusted, turn the joint nut (2) located at the transmission end of the clutch cable in or out, as necessary to achieve the proper play.
  3. Once the correct pedal free-play is obtained, check the free-play on the release arm (c), it should be 0.02-0.06 in. (0.5-1.5mm).
1999-01 Models These vehicles are equipped with a hydraulic clutch system. No adjustment is necessary.

Nov 05, 2010 | 1999 Suzuki Vitara

1 Answer

83 1000 sporster clutch adjustment xlh

Loosen clutch cable adjuster locknut and the front of the outer primary cover and turn the cable adjuster inwards until a large amount of free play at the hand lever on the handlebar is recognized.

Remove the clutch adjuster access plug, Loosen the adjuster locknut and turn the screw inwards until it becomes harder to turn (starts to release the clutch) and continue turning 2 more turns to be sure clutch is disengaged.

Adjust all the free play out of the clutch cable by turning the cable adjuster in the front of the outer primary outwards. Do not put any tension on the cable, just adjust all the freeplay out of the cable and tighten locknut on the primary cover.

Now, Back off the adjuster screw at the release mechanism until the clutch is engaged and the screw turns freely. Then turn inwards until it just bumps and then back off 1/8 to 1/4 turn. Locknut the locknut down and install the access plug. There should be about a 1/16" free play at the hand lever.

good Luck

Aug 28, 2010 | 1979 Harley Davidson XLH 1000 Sportster

1 Answer

2000 FXSTD Softail Duece: Clutch is engaging too late almost at the full out...

The clutch is most likey improperly set. What needs to be done is the clutch cover taken off, loose the cable adjuster backed way off and then set the clutch rod first by taking up all the end play and then turning out screw 1/2 turn, hold screw and tighten lock nut. The cable can now be adjusted so there is about 1/2" free play at the end of the lever

May 16, 2010 | 2000 Harley Davidson FXSTD Softail Duece

1 Answer

Need a 2003 polaris preditor clutch diagram

Try to adjust the play in the cable at the clutch perch, leaving play in the cable. If that is ok, then check the push rod adjustment if it has one. Bottom out the push rod screw and thebn back it off 1/4- 1/2 turn out. Chaz Moto DC

Jan 21, 2010 | 2003 KTM EXC 250 Racing

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

I would like to see exactly where you would adjust the clutch cable.demonstrate please.

Start at the clutch cable, loosen the locknut and screw the cable in so that there are no threads showing (till the adjuster touches the locknut.

You have to remove the derby cover (the big round cover with 5 screws on the outer primary) so the bike has to be sitting upright or the primary fluid will leak out.

Remove the derby cover, get an 11/16 (i think) socket and loosen the lock nut on the end of the clutch basket (use a hammer to tap the ratchet and loosen the nut).

Unsrew the nut a few turns and get an allen wrench (I forget what size but find one that will fit in the end of the rod that you just loosened up the nut on)

Using the allen key turn the rod in untill the clutch just start to engage, stop there then turn the allen 1/2 a turn out then using the ratchet and socket tighten the lock nut on the end of the clutch basket (tap the ratchet with a hammer to tighten so that the rod you just adjusted 1/2 a turn out does not move.

Now go back to the clutch cable and screw the cable back out so that you can see the clutch lever start to tighten up. Adjust the cable so that when you grab and pull the cable just before the lever you get a space just wide enough to slip a quarter into. So where the cable goes into the lever you want a little freeplay, the correct freeplay is 1/16 to 1/8, about the width of a quarter. Tighten the locknut on the clutch cable and put the derby cover back on.

Thats all there is to it, I hope this is clear enough, any questions just ask.

Here is the instructions from the manual:

1. Position motorcycle on a suitable lift, upright and level.
Point front wheel straight ahead.
2. Remove five TORX screws with captive washers to detach
clutch inspection cover from primary chaincase cover.
3. Remove and discard seal.
4. See Figure 1-20. Add free play to cable.
a. Slide rubber boot (1) off cable adjuster.
b. Holding cable adjuster (2) with 1/2 in. wrench, loosen
jam nut (3) using a 9/16 in. wrench.
c. Turn cable adjuster (2) until there is a large amount
of free play at clutch hand lever.
5. See Figure 1-21. Loosen jam nut (1) on clutch adjuster
screw (2). To take up all free play, turn screw inward
(clockwise) until lightly seated. Activate the clutch lever to
verify the balls are seated in the ramps.
6. Back out adjusting screw (counterclockwise) 1/2 to 1 full
turn.Tighten jamnut to 72-120 in-lbs (8.1-13.6 Nm), while
holding adjusting screw with an Allen wrench.
7. Squeeze clutch lever to maximum limit three times, to set
ball and ramp release mechanism.
8. Check free play.
a. Turn cable adjuster away from jam nut until slack is
eliminated at hand lever.
b. See Figure 1-22. Pull clutch cable ferrule (2) away
from clutch lever bracket (3) to check free play. Turn
cable adjuster as necessary to obtain 1/16-1/8
in. (1.6-3.2 mm) free play between end of cable ferrule
and clutch lever bracket.
9. Hold adjuster with 1/2 in. wrench. Using 9/16 in. wrench,
tighten jam nut against cable adjuster. Cover cable
adjuster mechanism with rubber boot.

10. Install clutch inspection cover and new seal as follows:
a. Thoroughly wipe all lubricant from cover mounting
surface and groove in chaincase.
b. Position new seal (1) in groove in primary chaincase
cover and press each of the nubs on seal into the
groove. The nubs will retain seal in position.
c. Insert screw (with captive washer) through clutch
inspection cover and carefully thread it into the top
cover screw hole.
d. Start the remaining four screws (with captive
e. Alternately tighten screws to 84-108 in-lbs (9.5-12.2
Nm) following torque sequence shown in Figure 1-23.

Jun 10, 2009 | 2008 Harley Davidson FLHRC Road King...

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