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Old February 14th, 2020, 08:34 PM   #1
nocturncal member
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Name: Cal
Location: San Francisco
Join Date: Jun 2017

Motorcycle(s): '09 Ninja 250R

Posts: 177
Help! Clutch Pulley on Clutch Cover Binding

I'm trying to put my clutch cover back on after inspecting it, and the clutch pulley that the lower part of the clutch cable hooks into is binding. Like I have to put a significant amount of force to get it to move up and down.

It freely moves when the cover bolts aren't torqued down, but as soon as the clutch cover bolts are torqued to spec (78 in lbs) in a star pattern, the lever has a real hard time moving.

I faced the pulley in the toward position prior to putting the cover on, then twisted clockwise to lock it in.

Here's a video since I'm having a hard time describing it

Link to original page on YouTube.

Any ideas?

Last futzed with by nocturncal; February 14th, 2020 at 09:38 PM.
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