Clutch engagement issue - help?

02rsxpilot · September 30th, 2011, 06:04 PM

Hey all, my dad's 2009 Ninja 250 was bought used from a dealer, and ever since we got it the clutch engages super late, like, the last half-inch of travel if that. I know it's late because I bought a brand new 2010 250r at the same time and my clutch was way easier to use. Another interesting note is I believe his clutch lever is further from the handlebar than mine was, based on how easily (or not) I can cover it with my fingers. This might be a related issue.

I actually just sold mine (bigger bike time!) but I still ride my dad's and would like to fix this if possible, especially if we decide to sell his too. I've read the wiki and all that, and I've even adjusted the cable to almost identical settings as my 2010, but nothing seems to change when it engages.

Can anyone recommend a good DIY guide to either a) adjusting the cable to get the clutch to engage sooner in the lever's travel, and/or b) adjusting the distance the lever is from the handlebar (if that's even possible with the stock levers)?

streetsquid · September 30th, 2011, 06:30 PM

i asked the samething to a tech at my shop i go to all the time and he said it was the why the bike is,,,but i would like to see what everyone comes up with also

i put ajustable lever on it and made it better but still not 100% like my bigger bike

Cuongism · September 30th, 2011, 06:40 PM

Sounds like you have too much freeplay in the lever. There's two ways to adjust when it engages; at the lever itself and near the engine on the right side. Unfortunately stock levers can't adjust distance to the bars.

ninja250 · October 1st, 2011, 06:55 AM

Quote:

b) adjusting the distance the lever is from the handlebar (if that's even possible with the stock levers)?

eBay levers will help with distance to the lever.

It does sound like something is out of adjustment though.

Sometimes this is the type of behavior a bike will display before the clutch cable snaps too, be sure to go over the cable.

02rsxpilot · October 1st, 2011, 06:44 PM

Thanks for the help all. I was able to follow the instructions from Cuongism's photo and the second part of adjusting the lower part of the cable did the trick (loosen bolts, pull cable tight, tighten bolts back). I even got it too far at first, where the clutch engaged super early, and had to back it down a bit.

FWIW, after I got the clutch engaging in the right place, it definitely also adjusted how far the clutch was from the handlebars (ie: before, I could get 2.5 fingers' last digit around the lever, now I can get 3 fingers, just like my 2010's clutch). Obviously this is directly correlated to when the clutch engages, so I'm not claiming the levers are adjustable persay.

In this case I was fairly certain the cable and clutch were fine because the bike barely has 2,000 miles on it.

September 30th, 2011, 06:04 PM	#1
02rsxpilot ninjette.org newbie Name: Derek Location: California Join Date: Sep 2011 Motorcycle(s): 2010 Kawasaki Ninja 250r Posts: 2	Clutch engagement issue - help? Hey all, my dad's 2009 Ninja 250 was bought used from a dealer, and ever since we got it the clutch engages super late, like, the last half-inch of travel if that. I know it's late because I bought a brand new 2010 250r at the same time and my clutch was way easier to use. Another interesting note is I believe his clutch lever is further from the handlebar than mine was, based on how easily (or not) I can cover it with my fingers. This might be a related issue. I actually just sold mine (bigger bike time!) but I still ride my dad's and would like to fix this if possible, especially if we decide to sell his too. I've read the wiki and all that, and I've even adjusted the cable to almost identical settings as my 2010, but nothing seems to change when it engages. Can anyone recommend a good DIY guide to either a) adjusting the cable to get the clutch to engage sooner in the lever's travel, and/or b) adjusting the distance the lever is from the handlebar (if that's even possible with the stock levers)?

September 30th, 2011, 06:30 PM	#2
streetsquid ninjette.org member Name: Steve Location: CT Join Date: Sep 2011 Motorcycle(s): 2011 ninja 250,2005 suzuki drz400 supermoto,2005 cr150f supermoto,2009 klx 110,1998 Z-50 Posts: 44	i asked the samething to a tech at my shop i go to all the time and he said it was the why the bike is,,,but i would like to see what everyone comes up with also i put ajustable lever on it and made it better but still not 100% like my bigger bike __________________________________________________ SQUID-Rider who overestimates his abilities.And rides Really slow in the corners,and sudden bursts of acceleration when a straight appears.Squids wear no protection,an thinks there invincible.

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September 30th, 2011, 06:40 PM	#3
Cuongism ninjette.org certified postwhore Name: Cuong Location: San Diego Join Date: Jul 2010 Motorcycle(s): 2008 Ninja 250r, 2007 Daytona 675 Posts: A lot.	Sounds like you have too much freeplay in the lever. There's two ways to adjust when it engages; at the lever itself and near the engine on the right side. Unfortunately stock levers can't adjust distance to the bars.

October 1st, 2011, 06:44 PM	#5
02rsxpilot ninjette.org newbie Name: Derek Location: California Join Date: Sep 2011 Motorcycle(s): 2010 Kawasaki Ninja 250r Posts: 2	Thanks for the help all. I was able to follow the instructions from Cuongism's photo and the second part of adjusting the lower part of the cable did the trick (loosen bolts, pull cable tight, tighten bolts back). I even got it too far at first, where the clutch engaged super early, and had to back it down a bit. FWIW, after I got the clutch engaging in the right place, it definitely also adjusted how far the clutch was from the handlebars (ie: before, I could get 2.5 fingers' last digit around the lever, now I can get 3 fingers, just like my 2010's clutch). Obviously this is directly correlated to when the clutch engages, so I'm not claiming the levers are adjustable persay. In this case I was fairly certain the cable and clutch were fine because the bike barely has 2,000 miles on it.