Adjusting clutch - Snapper Garden

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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).

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).

If the clutch lever is high (or engages at almost full release) then there is two options. 1, adjust the screw on the the lever itself, loosen the lock nut and turn in to adjust. 2, your clutch is worn beyond adjustment, replace clutch pak

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

Your clutch is not hydraulic but is supposed to self adjust. Try the procedure below to help it adjust. If it will not adjust, the clutch may be worn out.

ADJUSTMENT

Free-Play See Figures 8, 9 and 10
The clutch free-play is adjusted automatically by a built-in clutch control mechanism. This device allows the clutch controls to self-adjust during normal operation.
The system consists of a spring-loaded gear quadrant, a spring-loaded pawl and a clutch cable which is spring-loaded to preload the release lever bearing. This compensates for movement of the release lever, as the clutch disc wears. The pawl, located at the top of the clutch pedal, engages the gear quadrant when the clutch pedal is depressed and pulls the cable through its continuously adjusted stroke. Clutch cable adjustments are not required because of this feature.

Fig. Fig. 8: Clutch self-adjusting system component identification for the 3.8L engine


CHECKING ADJUSTMENT
The self-adjusting feature should be checked every 5,000 miles (8,000 km). This is accomplished by ensuring that the clutch pedal travels to the top of its upward position. Grasp the clutch pedal with your hand or put your foot under the clutch pedal, and pull up on the pedal until it stops. Very little effort is required (about 10 lbs./4.5 kg). Finally, depress the clutch pedal and listen for an audible "click.'' If you hear a sound, the clutch was in need of adjustment, and it has just adjusted itself.

Slide the rubber boot away from the clutch cable adjuster.
Loosen the cable locknut and turn the adjuster to provide as much cable slack at the clutch lever as possible.
Support the bike so that it's sits straight up.
Remove the clutch inspection cover.
Slide the spring with the attached lockplate off of the adjusting screw flats.
Turn the clutch adjusting screw counterclockwise until the screw stops. Then turn the clutch adjusting screw clockwise 1/4 turn.
Install the lockplate and spring onto the adjuster screw flats. You may have to turn the adjuster slightly to get the lockplate to line up.
Reinstall the clutch inspection cover and O-ring.
Adust the clutch cable at the cable adjuster all the way out and work the clutch a time or two. Now adjust the cable so that you have between 1/16" and 1/8" of freeplay at the clutch lever.
Tighten the cable adjuster locknut and replace rubber boot.
Good Luck

There is an adjustment for the clutch pedal under the dash where the push rod goes thru the firewall. There is only aprx. 1/2" of adjustment so be careful when making an adjustment, if your clutch is slipping then you need to shorten the throw of the push rod.

The clutch cable for your vehicle is an auto adjust clutch cable... assuming it is using oem equipment. if you tension seems incorrect you may want to pick up this Manual adjust clutch cable http://www.germanautoparts.com/Volkswagen/Jetta/Clutch/39/11 the auto adjust ones tend to go out and ruin your clutch. the manual adjust is a direct swap out for the auto adjust. if you need info on how to install please reference this site http://forums.vwvortex.com/zerothread?id=1569293