CLUTCH OPERATING MECHANISM ADJUSTMENT
Correct adjustment of the clutch operating mechanism is of the utmost importance and
the following instructions must be carefully observed.
In order to understand the method of clutch withdrawal a study of illustrations 14 and 15
should be made. See also paragraphs 7 and 8, page 41 (Transmission Service).
To enable the clutch to function satisfactorily 1/8" to 3/16" free movement of the opera-
ting cable is essential. This is checked by lifting the outer casing of the clutch cable at the
position where it enters the screwed adjuster on the kick starter case cover. If the
adjustment is correct it should be possible to freely move the casing up and down with
the fingers 1/8" to 3/16".
If the free movement is excessive causing clutch drag or noisy gear changing, adjustment
should be made as follows.
Release the clutch cable adjuster lock nut and then screw in the adjuster as far as it will
go to ensure that the operating lever B (illustration 15) is in its normal position.
Now turn to the opposite side of the cycle and remove the domed clutch cover secured
by eight screws.
Then using the sparking plug box key supplied in tool kit, loosen lock nut F.
Then with a screw driver gently screw in the thrust cup G until contact with the thrust
rod can be felt after which unscrew exactly one half turn and then securely retighten the
lock nut F taking care to observe that the screwed thrust cup does not also turn while
doing so.
Replace the clutch cover and then make the final adjustment by unscrewing the cable
adjuster until the recommended free movement of the casing is obtained after which
retighten the cable adjuster lock nut.
As a result of wear of the clutch friction plate inserts after prolonged use, the plates
tend to close up towards each other. This will have the effect of reducing the free
movement in the operating mechanism referred to above.
Clutch slip resulting from lack of free movement will rapidly ruin the inserts and may
generate sufficient heat to soften the clutch springs. Therefore should clutch slip develop
an immediate check of free movement must be made.
In this case after slacking off the cable adjuster, unscrew the cup G a turn or two and
then gently screw in until contact with the thrust rod is felt after which as already
detailed it should be unscrewed exactly one half turn before retightening the lock nut F.
Lastly adjust the cable for the specified free movement.
To remove a clutch control cable
Remove the oil filler cap from the kick-starter case cover.
Screw right home the clutch cable adjuster that is located in the top of the kick-starter
case cover.
Disengage, from the operating lever, the clutch cable inner wire by operating through
the oil filler cap opening.
Completely unscrew the clutch cable adjuster.
Disengage, from the handlebar operating control lever, the clutch inner wire.
Pull cable, by its lower end, till removed from the machine, easing it through the frame
cable clips while doing so.
To replace a clutch control cable
reverse the above instructions and, finally, adjust as detailed earlier.
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