Major Clutch Problem? Help!

[MaxxVE]

Hi Everyone -

Long time lurker, first time poster. I've got a problem with my clutch. Down at the clutch lever I noticed that there was no tension at the lever. What's worse, (maybe) is that I can actually pull the lever right out of the cover.

I made a video to show what I'm describing.

Bike details:
2006 Ninja 250
1,800 miles

http://www.youtube.com/watch?v=KVDZL19_7eM

[Motofool]

Welcome to our site, Grant !!!

You don't have a problem, just lubricate that thing (be gentle, there is a seal at the top of the clutch cover), insert it all the way down and rotate it clockwise (it may need some turning on the opposite direction first) until the notch at the bottom grabs the plunge that runs along the central axis of the clutch's body.

http://faq.ninja250.org/wiki/Adjusting_the_clutch_cable

When properly engaged, it should look like this:

[MaxxVE]

Thanks for the quick reply! It seems that I'm able to get the lever 100% down while in the 10oclock position. As soon as I start to rotate it clockwise it feels like it try's to catch something but lifts out and continues to spin freely until the 1oclock position.

For whatever reason I can't get it to connect or latch onto the clutch pin like its supposed to.

Here is another video: http://www.youtube.com/watch?v=orz7LTBTnD8

[Motofool]

Originally Posted by MaxxVE

.......For whatever reason I can't get it to connect or latch onto the clutch pin like its supposed to.

I see.
It has been easy for me before, but don't remember exactly at what angle it engages.

I hope @alex.s could give us a hand here.
He posted a detailed method some time ago.

Here is that old thread:
http://www.ninjette.org/forums/showthread.php?t=129992

Quoting his post:

"if you are standing on the right of the bike looking at it, the bike would be oriented at 9'o'clock to 3'o'clock right? with the right foot peg pointing at 6'o'clock... so slide the clutch pull lever thing down with the lever pointing at about 4'o'clock... slide it down and wiggle it until it stops... it'll be sticking out about half an inch. now rotate clockwise, it will catch the little pull grab on the inside and will pull itself down all the way as you rotate it up to 12'o'clock. from here you can put the bottom of the clutch cable in, then run it up to the clutch lever. put it on the clutch lever but dont tighten anything. now put the bottom of the clutch cable in its little holder at the bottom at the tighest range it will go (top nut of the two on the bottom tightened as far as it will go). now you can adjust tension at the top on the clutch perch."

[MaxxVE]

I tried the alex.s method a couple times this morning before heading to work. Unfortunately, I didn't have any luck. I'll have to play around with it some more tonight.

Would it help if the bike was running? Maybe leaned to the right side to get that pin sticking out a bit more for the lever to catch?

[baxtc1]

Could you post a picture of the pin, particularly the notched section.
Maybe it is damaged and not catching the rod.

[MaxxVE]

I have only pulled it all the way out that one time in the first video link. I wasn't sure if it would hurt anything to keep pulling it out and putting it back in.

**Edit: I just watched the video again and I think it's pretty clear. If you need to see more let me know and i'll pull it out again and take some pictures later tonight.

[agentbad]

That bird had good aim Motofool.

[Motofool]

Originally Posted by MaxxVE

..........Would it help if the bike was running? Maybe leaned to the right side to get that pin sticking out a bit more for the lever to catch?

Yes, it is possible that the plunge is not all the way out.
I am not sure there is something inside the clutch prevents that from happening.

I would try seeing down the well and using a long little flat screwdriver to fish the thing.

Leaning the bike right while the engine is working may help as well.

Sorry I cannot help you better.

[alex.s]

you snapped the head off the clutch release pin.

drain the oil, remove the clutch cover, remove the top of the clutch with the 4 or 5 bolts with springs, then remove and replace the clutch release pin. make sure you find the piece that snapped off, you'll probably need to remove the bottom cover on the oil pan and the screen. once its replaced as you slide the clutch arm back up it will grab the clutch release pin, pulling the clutch apart

remember that paper gasket on the clutch cover tears every time from the kawi bond they put on the case split. so get a new gasket with the new clutch release pin.

[alex.s]

also- the video only shows one side of the clutch release linkage. its the other side that is important. the part that grabs the head of the release pin.

[MaxxVE]

Yikes, that would really suck if its the pin. Could I look down into that area after removing the clutch lever and see the head of the pin sticking out?

There is something there contacting the lever because it won't just go down into the hole without spinning it the right way. I would think if that pin was broke it would free spin?

[Motofool]

What is the history before this point?

[MaxxVE]

I'm the second owner, I just bought the bike a couple weeks ago. It was running fine at that point but the clutch adjustment screw at the handlebar was broken because the previous owner had tipped it over (low speed in a parking lot). When I removed the clutch cable from both ends that is when the problem started.

[djjontran]

Nice! If that's the only problem that should be an easy fix!

[MaxxVE]

Originally Posted by djjontran

Nice! If that's the only problem that should be an easy fix!

It probably should be an easy fix but I haven't yet been able to get the lower clutch lever to work right.

Can someone close to their bike do me a favor and measure the distance of that lower clutch arm to the cable mount in both the engaged and disengaged positions? I'm trying to find out what the normal travel should be. Thanks in advance!

[Motofool]

Originally Posted by MaxxVE

I'm the second owner, I just bought the bike a couple weeks ago. It was running fine at that point but the clutch adjustment screw at the handlebar was broken because the previous owner had tipped it over (low speed in a parking lot). When I removed the clutch cable from both ends that is when the problem started.

Then, no abnormal stress or load should have been over that plunge to damage it.

Try the previous suggestions before opening the cover.

[MaxxVE]

Is this great iPhone photography or what?! :P

Thankfully the pin is not broken. I'm still messing around with it. If somebody could measure the distances or positions that the lever should be in I'd appreciate it. That should help me trouble shoot.

[Motofool]

Great, it is there !!!

I cannot measure mine now, but the normal position is like in my previous picture and the range of movement is identical (at the point of connection of the cable) to the range of movement of the hand lever.

Keep trying Alex's description.

[7oxSin]

its kinda hard to tell, looks to be 3 inches and then 2.5 when you pull the clutch

here are some ****** phone pics





hope that helps, dont mind the foot, just in there cuz im secksy!

[The_big_dill]

That notch on the rod that you are pulling on simply needs to grab that nipple in the hole. Like mentioned before, just try again. Stick the thing in as far as it will go (twist to find the lowest point if you have to) and then turn clockwise until it catches the nipple.

[MaxxVE]

I know, for something that should be so simple I can't see to get it to go. I'll monkey around with it tonight. Last night I was changing the spark plugs.

Thanks 7oxSin! That should help me determine when it should "catch" the pin and where it should pull it to.

[mgorven]

Originally Posted by The_big_dill

Stick the thing in as far as it will go (twist to find the lowest point if you have to) and then turn clockwise until it catches the nipple.

I found that pushing it all the way in caused it to not catch the rod, I had to lift it 0.5-1cm to make it catch.

[Motofool]

Originally Posted by The_big_dill

........Stick the thing in as far as it will go (twist to find the lowest point if you have to) and then turn clockwise until it catches the nipple.

[Motofool]

Originally Posted by MaxxVE

I know, for something that should be so simple I can't see to get it to go. I'll monkey around with it tonight........

Maybe the shaft-lever doesn't have to go all the way down.

It is the sharp edge of that shaft what does the pulling job, the oval notch is just to clear the neck of the plunge as the shaft rotates clockwise.

[baxtc1]

The position you need to put the lever in:


Lever in position:

[alex.s]

we still do not know what the correct side of the lever looks like. maybe the grabber part is broken off?

op says "no tension down at the lever" but then also says that it wont freely spin. that means that something is stopping it. perhaps there actually isn't any problem? when you reconnect the clutch cable and adjust the tension, what happens when you pull the lever? nothing? is the problem that you don't know how to adjust the cable tension?

[alex.s]

here is another thought- maybe your clutch plates are so worn that the lever extends naturally that far up (as seen in the video)

[MaxxVE]

Here is a picture of the back side. Everything appears to be intact.

I am waiting on that clutch adjustment screw to come in so I can reattach the cable.

[MaxxVE]

I just wanted to update this thread. The part I needed arrived and after assembling everything the clutch seems to be working fine! I think I need to lube the cable because the pull is somewhat difficult but that's easy enough to do.

Thanks for all the help!

[Motofool]

Originally Posted by MaxxVE

.......Thanks for all the help!

[7oxSin]

glad we could help, if the cable is rough deff lube it, also pick up an extra cable for when yours snaps. it will save you like 10-20$ and a tow bill.
just call ur old lady and be like:
"no! it looks like a black jump rope, its on the top shelf, just grab it and come meet me!"

[The_big_dill]

Originally Posted by Motofool

Dirty, dirty mind. Now that i read it though...