Clutch snapped

[The_big_dill]

Hi all,

About half way through my regular 50km ride to work today i pulled in the clutch for the last time for this ride.

Clutch wouldn't release, i couldn't get into neutral, let the bike stall after i pulled into the nearest plaza.

Took a look at the bike and the clutch cable is intact, its something behind the crankcase cover, a spring?

Any ideas what it could be?

[Racer x]

The thing inside the clutch cover should rotate and pull out of the cover once the cable is removed. Pull that out and look at it. Or post up some photos. This is not a big deal what what ever it is.

[Motofool]

Originally Posted by The_big_dill

Took a look at the bike and the clutch cable is intact, its something behind the crankcase cover, a spring?

For riding home with no clutch:

http://faq.ninja250.org/wiki/Can_I_r...able_breaks%3F

[The_big_dill]

I already got a tow on the bike, lucky for us to have a van

When i set out today, the clutch lever never seemed to retract fully and be fully extended whenever i let the clutch off, then it finally broke, whatever the problem is.

[Lychee]

Originally Posted by The_big_dill

I already got a tow on the bike, lucky for us to have a van

When i set out today, the clutch lever never seemed to retract fully and be fully extended whenever i let the clutch off, then it finally broke, whatever the problem is.

It had probably stretched enough that it was too loose to pull the clutch arm. Not an expensive fix, good thing you didn't crash!

[The_big_dill]

Originally Posted by Lychee

It had probably stretched enough that it was too loose to pull the clutch arm. Not an expensive fix, good thing you didn't crash!

It is an '87, but are you reffering to the spring?

[Lychee]

Cable. Have you tried tightening the adjuster near the lever?

[Motofool]

Originally Posted by The_big_dill

I already got a tow on the bike, lucky for us to have a van

When i set out today, the clutch lever never seemed to retract fully and be fully extended whenever i let the clutch off, then it finally broke, whatever the problem is.

Referring to schematic of post #3:

Bottom of part 13102 has a notch that grabs part 46102 and pulls it out together with parts 92045 and 13187 as you press the clutch lever at the handle bar.
That way, the friction discs are liberated from the pressure of the six springs 92081.

[The_big_dill]

Originally Posted by Motofool

Referring to schematic of post #3:

Bottom of part 13102 has a notch that grabs part 46102 and pulls it out together with parts 92045 and 13187 as you press the clutch lever at the handle bar.
That way, the friction discs are liberated from the pressure of the six springs 92081.

That makes sense, i will be working on this tomorrow after work.

I really appreciate the help and pictures guys

[The_big_dill]

Here is an update:

I like to over think things, and after i pulled apart the crankcase cover and got as far as the clutch plates i saw nothing wrong... I tugged at the clutch cable and...



In the process i broke the sight glass for the oil level... suits me right for over thinking the problem.

What is the torque spec on the clutch spring bolts?

[Motofool]

Originally Posted by The_big_dill

..........
What is the torque spec on the clutch spring bolts?

For the sight glass:
http://faq.ninja250.org/wiki/How_do_...sight_glass%3F

For the torque:
6.5 ft-lbs (77.9 in-lbs)

......... according to:
http://faq.ninja250.org/torque/ex250f/

[The_big_dill]

Originally Posted by Motofool

For the sight glass:
http://faq.ninja250.org/wiki/How_do_...sight_glass%3F

For the torque:
6.5 ft-lbs (77.9 in-lbs)

......... according to:
http://faq.ninja250.org/torque/ex250f/

You are awesome!

Quick and to the point.

In any case, no store within 100km of me had the clutch cable and couldn't even get anything until end of this month. So i ordered one from ebay ($17 + $5 shipping)

Site glass cost me $10, New gasket is $14 and kickstand spring is ~$8.

Cheers,

Thanks for all your help.

[Motofool]

Not so much

You are welcome

[lgk]

Make sure to lube the cable often, check the adjustment at every oil change.

The cable off my new bike only lasted 6 months being outdoors with no lube.
it gradually frayed apart, until it let go at a stop light. Forcing me to ride home clutchless.

[The_big_dill]

Lucky for me, this thing fits in a Grand Caravan.

Last time i didn't support it enough and i damaged some of the fairings though... Will have pictures soon.

[Lychee]

Voila! You can also source a used one from craigslist as I did awhile back. $10 seemed fair at the time, but if a new one is only $23, maybe I should have went new...

[The_big_dill]

Hey, so i installed my clutch cable. I had to tighten it all the way so there is no free-play in the clutch lever, but now its stiff the entire time i pull the clutch lever.

Thinking about it, i think i overtightened the clutch spring bolts, what do you guys think?

[The_big_dill]

Originally Posted by Lychee

Voila! You can also source a used one from craigslist as I did awhile back. $10 seemed fair at the time, but if a new one is only $23, maybe I should have went new...

I found a place that sells parts to dealers, sold the cable to me for $20, i installed it right away

[lgk]

Originally Posted by The_big_dill

Hey, so i installed my clutch cable. I had to tighten it all the way so there is no free-play in the clutch lever, but now its stiff the entire time i pull the clutch lever.

Thinking about it, i think i overtightened the clutch spring bolts, what do you guys think?

You need a little play to be sure the clutch is fully engaged.

did you rotate the cable tensioner all the way down into the handle bar.

[The_big_dill]

Originally Posted by lgk

You need a little play to be sure the clutch is fully engaged.

did you rotate the cable tensioner all the way down into the handle bar.

It was the clutch spring bolts being over torqued.Thanks for your help

The new clutch cable has a smaller angle on the metallic piece near the clutch lever connection, meaning when i sit on the bike, it literally sticks out in front of the RPM gauge. Although, it isn't OEM as Kawasaki discontinued it for the E series.