TS250/1 - How do you adjust clutch?

[andy288]

Probably overlooking something really simple but used up all adjustment at the clutch lever end - how do you adjust at the engine end? Couple of images so you can see the problem!

Guess its really simple but knowledge is power I suppose and if you don't know or ain't sure best ask!

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[therealche]

First you have to adjust the clutch end correctly. Best seen in this video

https://youtu.be/6ptXHE2i0x0?t=50m13s

[andy288]

Ta for the reply.

Watched that video before and set the distance as specified (see my image), thing is though when I connect the cable and tension using the adjuster on the handlebar lever I use up all the adjustment way before tension is acheived?

[DAVID THOMPSON]

if everything seems correct
compare clutch cable lengths
maybe have wrong one installed

[therealche]

Worth checking the cable... some replacement ones are just wrong.The free play of a clutch cable should be 82mm. That is measured between the end of the ferrule and the start of the nipple. Oh and check that the black plastic bung thing in the end metal tube hasn't been butchered. I had one that seemed to hold the cable but when you pulled the lever the outer slipped through!

[andy288]

All sorted now thanks!

It was indeed the black plastic cable stop, split a little too much and letting the outer slip through when under tension. Difficult to spot with the rubber boot which covers it in situ!

[MotoMZ]

https://www.ebay.co.uk/itm/123679485503

[Blurredman]

I actually find it easier to place the 'holding bracket' to quite a tight position. This way, the adjustment at the handlebar isn't out like an inch and a half..