Question about 2002 Yamaha Xv 250 Virago S

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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

Posted by j0hn5teel21 on

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Geoff watson

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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

Posted on Apr 02, 2010

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1 Answer

Suzuki RM80 clutch will not disengage.


Hey Anon,
First, make sure the clutch is adjusted correctly..This video is a basic tutorial.. use it for a guide BUT DO the steps as I TELL YOU..
1. Loose the cable adjuster at the handle bar.. run the adjuster in - (give it as much slack as you can)
2. The clutch actuator lever on the engine case should be able to move about 8mm (.325") before it starts to disengage (gets hard to move)..
3. Adjust the cable at the bottom adjustment to take up any slack at this point.. ..you MIGHT/should be able to feel some (NOT FULL TENSION) clutch disengagement in the handle bar (clutch) lever at this point.. IF YOU CAN'T - tighten the cable at the bottom adjustment ONE round at a time until you can feel (a small amount) tension and have at least/about 12mm (.48") max. of play in the lever (BETWEEN THE LEVER AND THE MOUNT when YOU START TO FEEL TENSION... - NOW - in the clutch lever (handle bar).. when you can feel tension in the lever... >> you should start adjusting the lever to have (at least) approximately 1/8" - (3mm) of play (gap) between the lever and mount.. when you have this set correctly, the clutch adjustment question is eliminated. If the adjustment has not helped and you had to do A LOT of adjusting. you need to replace the clutch cable.. and do this adjustment process again. NOW adjustment is NOT part of your problem. If this fixes your problem GREAT!!
.. If not.. now.. we have to move internally..The next issue will be grooves worn into the arms of the clutch basket be the fiber clutch plate ears..(see picture) (the ones that keep the plates stationary when you shift to help disengage the clutch). Also check the actuator arm (see picture below) for wear..



. How to Adjust Clutch
clutch adj-1yabyasfolpfscp5rjzzy1he-2-0.jpg

clutchbasket1-1yabyasfolpfscp5rjzzy1he-2-2.jpg clutchparts-1yabyasfolpfscp5rjzzy1he-2-5.jpg
Ok.. if you have gotten this far and everything seems good, reinstall AFTER YOU HAVE METICULOUSLY CLEANED THE BASKET!! The clutch should be working now.
Congrats!! If you need professional port work contact me..
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1 Answer

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Keep your fingers crossed that it is simply a loose pinch bolt on the shift arm. To check, look closely at the shift shaft end as you move the shifter up and down. If the shift shaft is not moving with the shift lever, the pinch bolt may be loose, or more likely, the splines have worn out on the shifter due to a loose bolt. To fix, grab a 10mm wrench and loosen and remove the pass-through bolt that is on the shift lever and replace the shift lever. I provided a link to a used one on eBay for $15. If the splines on yours are good and the bolt is tight with the shift shaft moving properly, then the internal shift fork is damaged which will require a teardown. 91 Kawasaki EL 250 EL250 Eliminator SHIFT LEVER

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1 Answer

Ktm 85 egine noise,and just ad topend rebuild


Instructions
    • 1 Take the motorcycle for at least a fifteen minute test drive. Use this time to determine if the clutch needs to "grab" more or less. For example, if you pull in the clutch lever and it is difficult to shift, it grabs too much. On the other hand, if when you let the clutch lever out the motorcycle is low on power, it is not grabbing enough.
    • 2 Set the motorcycle on its kickstand or, if like some dirt bikes, it does not have one, prop it against a solid object so that it will not fall over while being worked on.
    • 3 Loosen the clutch cable if the clutch needs to "grab" more, via the clutch cable adjuster bolts near the crankcase, until there is a small amount of play in the cable. You should be able to move the clutch lever just slightly with no change in the clutch's actuation.
    • 4 Tighten the clutch cable if you need the clutch to "grab" less. Tighten the cable until there is only a small amount of play left in the cable. Pulling the lever from now on will make a much larger difference in clutch actuation.
    • 5 Tighten the clutch cable adjusters near the crank case and take the motorcycle for a test ride in an open, private area. While riding, use your left hand to adjust the barrel adjuster where the cable housing meets the clutch lever to fine tune the adjustments made previously. When you feel the clutch is set up properly, return to your work area and tighten the barrel adjuster stop so that it will not loosen as you ride.

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1 Answer

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Getting this, to not be so jerky, may be as easy as adjusting the clutch. open up the derby cover and ..

1)Collapse the adjuster on the cable sleeve all the way.

2)Pull the lever against the bar and hold it there with slight force.

3)Turn the pushrod adjuster bolt in while holding the lever against the bar lightly until it starts to force the lever away for some distance. (Do this more than once to get the feel). While keeping light pressure on the lever back the adjuster bolt out just until the lever touches the bar again and then another little bit, about 1/2 turn , then lock it.

4)Adjust the cable freeplay at the lever for 1/16" free play.

You should be good to go .

Always adjust the clutch on a cold bike for best results.

**It's better to adjust the clutch so that it starts to grab at least an inch or more from the bar for complete disc separation, which translates into better/quieter shifting.Using this method, you can "feel" where the lever is going to grab with a little practice.

Buy yourself a cheap 11/16 deep well socket and weld a nut on top of it. This makes the perfect tool for the adjuster lock nut. You can then use an Allen wrench inside the socket and a wrench on the nut you have just welded on. Makes it a lot simpler.

You can also see "clutch adjustment by the book" in this same forum found-- HERE.. Hope this helps Fix Ya up..

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2 Answers

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If it's not the clutch dragging, check for a faulty kickstand switch.

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2 Answers

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1 Answer

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1 Answer

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1.http://en.wikipedia.org/wiki/Model_T_Ford
2.http://www.modeltcentral.com/transmission_animation.html



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1 Answer

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