5.6 - Clutch Lever & Cable Adjustment

In order, to ensure the best performance and durability from the clutch, always be sure you have proper clutch free-play. Free-play is needed to ensure that the clutch has room for wear. A clutch with no free-play will begin to slip as the discs wear down. Failure to fix a slipping clutch can cause clutch damage. To check the free-play, simply pull on the clutch lever. The lever should move very easily within the free-play range before you feel the clutch begin to engage. If too much or too little free-play exists, adjustments are needed.

1. Clutch Lever Adjustment (If applicable)

The distance between the grip and the tip of the clutch lever can be adjusted to suite the size of your hand.

1. Loosen the lock nut
2. To make the position of the clutch lever farther away from the tip of the grip, turn the adjuster screw in a clockwise rotation.
3. To make the position of the clutch lever closer to the tip of the grip, turn the adjuster screw in a counter-clockwise rotation.
4. Once you are comfortable with the position of the lever, tighten the lock nut securely.
5. FREE-PLAY: 10mm-20mm (0.4-0.8 in.)

1. Cable End Adjustment (free-play)

Minor adjustments are generally made with the clutch cable end adjuster.

1. Turning the cable end adjuster in the        direction will increase the free-play
2. Turning the cable end adjuster in the                direction will decrease the free-play.

If the adjuster is threaded out near its limit or the correct free-play cannot be reached, turn the adjuster all the way in and back in out one full turn and make the adjustment with the integral cable adjuster on the engine.

1. Integral Cable Adjustment

The integral cable adjuster is used if the cable end adjuster is threaded out near its limit, or the correct free-play cannot be obtained.

1. Pull back the black rubber cover
2. Loosen the lock nut
3. Turn the adjuster nut to obtain the specified free-play.
4. Tighten the lock nut. Check the free-play

Make sure the gear is in Neutral. Start the engine and pull the clutch lever in and shift into gear. Make sure the engine does not stall and the motorcycle does not creep. Gradually release the clutch lever and open the throttle. Your motorcycle should now move smoothly and accelerate gradually.

If you can’t get the proper adjustment, or the clutch does not work properly, the cable might be kinked or worn out or the clutch friction discs may be worn out. Take to your local AJ1 dealer for inspection.