SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Clutch cable adjustment should be checked before (and during) each ride. The clutch cable must be adjusted whenever the clutch cable free play is not within specification.
Free play is checked between the clutch lever holder on the left handlebar and the pivot end of the clutch lever. Pull back the rubber dust cover. Measure the free play with a machinists rule or caliper while gently pulling on the clutch lever until resistance is felt.
Clutch Lever Free Play: 2-3 mm (0.08 – 0.12 in)
Adjustment
To adjust free play, pull back the rubber dust cover, loosen the knurled locknut on the clutch cable.
Turn the adjuster screw in or out until there are 5 – 6 mm (0.20 – 0.24 in) of threads visible past the locknut. Check the cable for any fraying of the inner cable or damage to the outer housing of the cable. Replace as necessary.
The clutch cable adjuster is located behind the oil filler cap on the right side of the engine.
Slide the dust cover back from the rear locknut. Loosen the locknuts all the way with a 12 mm socket.
Grip the clutch cable outer and pull it forward. Tighten the locknuts against the clutch cable stay.
Adjust the clutch cable free play to specification with the adjuster at the lever.
Tighten the lock nut securely.
Push the release lever forward and check the angle formed between the lever and the cable as shown by the yellow lines. This angle should be between 80 – 90 degrees. Also, inspect the clearance between the release lever and the clutch cover. This clearance should be 1 – 3 mm (0.04 – 0.12 in). If either the angle or the clearance is out of specification inspect the clutch release components. See the Clutch topic for more information.