Maintenance - Major Service

8. Check and adjust the clutch

The clutch is adjusted correctly if there is the correct specified amount of free play in the cable measured between the handlebar lever butt end and the handlebar clamp and the clutch operates smoothly with no sign of slip or drag.

To adjust the clutch, slacken the handlebar adjuster locknut then rotate the handlebar adjuster as necessary until the distance between the forward edge of the clutch operating lever on the gearbox and the rear edge of the cable outer cover on the gearbox housing (ie the exposed length of clutch cable inner wire) is 75 + 1 mm (2.95 ± 0.04in). Tighten the handlebar adjuster locknut.

Slacken the locknut of the adjuster set in the clutch operating lever at the rear of the gearbox and slacken the adjuster screw by one or two full turns to check that there is no pressure on it, then screw it in until light resistance is encountered; do not over tighten the screw. Hold the screw steady and tighten the adjuster locknut securely. Use the handlebar adjuster to set the specified clearance at the lever, then tighten its locknut; operate the clutch lever once or twice to settle the cable. Check that the adjustment has remained the same, resetting it if necessary. Apply a few drops of oil to all cable end nipples, adjuster threads and lever pivots.

If the clutch still shows signs of slipping or dragging, or if it is very sudden in action, it must be dismantled for examination. On reassembly, the components should be lubricated, (where specified) to ensure a smooth action.

Refer to Chapter 2 - Clutch.

Measuring clutch cable free play 100 model shown

Use cable handlebar adjuster to set....

.... correct length of exposed cable inner wire, as shown

Clutch operating lever adjuster is used to set release mechanism

Where fitted, set side stand linkage so that free play is just eliminated with stand down