DIY How to Lube and Adjust the 250R Clutch Cable and How to Add 10 HP w/ one Mod!!! - Page 2

Momaru · July 6th, 2011, 08:04 PM

Dunno if you've already tried this but...

As an additional idea, grab the end of the cable and metal terminator cap. Align it so it makes a straight line with the adjuster screw, so there's no tension/pull on the adjuster from the cable. I had issues with moving the adjuster screw because the cable was pulling 'down' so hard the threads wanted to bind.

Basically just jiggle the cable while trying to turn the adjuster, see if that helps

jamesio · July 6th, 2011, 08:30 PM

Quote:

Originally Posted by kkim

sounds to me like you stripped/cross threaded the threads in the lever housing. take the clutch lever back off, and remove the cable. the adjuster (the piece with the bigger wheel on it) should be able to screw freely in and out of the lever perch.

does it?

if not, remove the adjuster from the clutch perch and inspect the threads in the clutch perch and adjuster.

Ya, I'm not going back out there to take pictures right now, but I think that's what it is. When I was trying to free the cable by pulling the clutch lever I had left the very end of the adjuster still screwed in lever holder by accident. When I pulled the lever a couple times I heard kind of a grinding sound and there were little black shavings on the fairing...it was only the very beginning so I thought I could work past it but I guess I effed it up bad. Do I gotta get a whole new housing?

Quote:

Originally Posted by Momaru

Dunno if you've already tried this but...

As an additional idea, grab the end of the cable and metal terminator cap. Align it so it makes a straight line with the adjuster screw, so there's no tension/pull on the adjuster from the cable. I had issues with moving the adjuster screw because the cable was pulling 'down' so hard the threads wanted to bind.

Basically just jiggle the cable while trying to turn the adjuster, see if that helps

Nope, it's stripped

kkim · July 6th, 2011, 08:43 PM

Quote:

Originally Posted by jamesio

Do I gotta get a whole new housing?

possibly... that's why you need to remove the lever and cable to get to the adjuster to find out exactly what's stripped/the problem. you may be able to clean out the perch and adjuster and things may work okay after that. if not, and if new perches are expensive, check ebay for a replacement.

jamesio · July 6th, 2011, 08:53 PM

Quote:

Originally Posted by kkim

possibly... that's why you need to remove the lever and cable to get to the adjuster to find out exactly what's stripped/the problem. you may be able to clean out the perch and adjuster and things may work okay after that. if not, and if new perches are expensive, check ebay for a replacement.

I'll go back out there in a few, see how bad it is, and post pics tomorrow. I looked on bikebandit and they are about $23

jamesio · July 7th, 2011, 11:46 AM

Good news, this morning I was able to screw the adjuster in and now everything is better

The cable is cleaned and lubed, and plenty of free play in the lever. I think before the friction zone was engaging near the end of the lever travel, now it is more in the middle. I took her for a ride and shifting seems even smoother now

The pazzo levers are great

kkim · July 7th, 2011, 11:48 AM

Squalo · July 21st, 2011, 11:31 AM

I have been unsuccessful in finding Tri-flow in my area, can anyone suggest something else? I was thinking of using the DuPont Teflon multi lube (same as chain), but someone on another forum said since its a dry lube, wont work as well.

Suggestions?
Cheers!

Shaol1n Monk · July 21st, 2011, 07:43 PM

hahaha! i just added an extra 20hp then with these ZX-R bar ends:

Mr KaNuke · October 6th, 2014, 09:40 PM

My adjuster knobs literally do not move (previous owners let it rust). Any tips on how you guys broke yours loose? or am i SOOL?

Alex · October 11th, 2014, 06:04 PM

Which adjuster knobs, up by the levers?

Mr KaNuke · October 11th, 2014, 06:40 PM

Quote:

Originally Posted by Alex

Which adjuster knobs, up by the levers?

Yes sir. I actually got them unstuck. Let em soak in some oil over night (sprayed them and forgot them) and by the next day I just took a pair of plyers and they moved pretty easily after that. Just had to break them loose. My clutch cable is so old though, I have it basically completely out as far as I can because of how stretched it was

Alex · October 11th, 2014, 06:42 PM

Sounds like it's time for some new cables soon.

July 6th, 2011, 08:04 PM	#41
Momaru ninjette.org certified postwhore Name: Paul Location: Roanoke, VA Join Date: Jun 2009 Motorcycle(s): 2008 Candy Plasma Blue 250R Posts: A lot.	Dunno if you've already tried this but... As an additional idea, grab the end of the cable and metal terminator cap. Align it so it makes a straight line with the adjuster screw, so there's no tension/pull on the adjuster from the cable. I had issues with moving the adjuster screw because the cable was pulling 'down' so hard the threads wanted to bind. Basically just jiggle the cable while trying to turn the adjuster, see if that helps __________________________________________________ Proud member of the Blue Army

July 7th, 2011, 11:46 AM	#45
jamesio ninjette.org guru Name: Moe Location: Earth Join Date: Jun 2011 Motorcycle(s): None Posts: 424	Good news, this morning I was able to screw the adjuster in and now everything is better The cable is cleaned and lubed, and plenty of free play in the lever. I think before the friction zone was engaging near the end of the lever travel, now it is more in the middle. I took her for a ride and shifting seems even smoother now The pazzo levers are great __________________________________________________ '09 Ninja 250R SE TB Slip-On l Puig DB l Pazzos l Pro-Grips

October 6th, 2014, 09:40 PM	#49
Mr KaNuke ninjette.org newbie Name: Eric Location: Chicago Join Date: Sep 2014 Motorcycle(s): 08 Ninja 250 Posts: 3	Rust My adjuster knobs literally do not move (previous owners let it rust). Any tips on how you guys broke yours loose? or am i SOOL?

October 11th, 2014, 06:04 PM	#50
Alex ninjette.org dude Name: 1 guess :-) Location: SF Bay Area Join Date: Jun 2008 Motorcycle(s): '13 Ninja 300 (white, the fastest color!), '13 R1200RT, '14 CRF250L, '12 TT-R125LE Posts: Too much. Blog Entries: 7	Which adjuster knobs, up by the levers? __________________________________________________ Montgomery Street Motorcycle Club / cal24.com / crf250l.org / ninjette.org ninjette.org Terms of Service Shopping for motorcycle parts or equipment? Come here first. The friendliest Ninja 250R/300/400 forum on the internet! (especially Unregistered)

October 11th, 2014, 06:42 PM	#52
Alex ninjette.org dude Name: 1 guess :-) Location: SF Bay Area Join Date: Jun 2008 Motorcycle(s): '13 Ninja 300 (white, the fastest color!), '13 R1200RT, '14 CRF250L, '12 TT-R125LE Posts: Too much. Blog Entries: 7	Sounds like it's time for some new cables soon. __________________________________________________ Montgomery Street Motorcycle Club / cal24.com / crf250l.org / ninjette.org ninjette.org Terms of Service Shopping for motorcycle parts or equipment? Come here first. The friendliest Ninja 250R/300/400 forum on the internet! (especially Unregistered)

July 7th, 2011, 11:48 AM	#46
kkim Join Date: Nov 2008 Posts: Too much.

July 21st, 2011, 11:31 AM	#47
Squalo ninjette.org member Name: Canada Location: Alberta Join Date: May 2011 Motorcycle(s): 09 Ninja 250 Posts: 55	I have been unsuccessful in finding Tri-flow in my area, can anyone suggest something else? I was thinking of using the DuPont Teflon multi lube (same as chain), but someone on another forum said since its a dry lube, wont work as well. Suggestions? Cheers!

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