Clutch adjustment? 97 Katana 600

[Stoeger]

How do I adjust the clutch on my bike? (Besides the little screw adjuster right on the clutch lever, that is already all the way out)

1st problem: The clutch lever is VERY STIFF to pull in, really is a hand workout to pull it. Can this be fixed?

2nd problem: Sometimes the starter won't engage because the sensor or whatever doesn't think the clutch is all the way in, like it's still engaged. I tend to think this because the bike barely rolls if I'm gear even with the clutch lever all the way pulled in... like the clutch is still dragging)... So it there an adjustment anywhere on the cable to give me more travel?

[sidecarguy]

if its too hard watch out and dont break it!
i broke my cable once and had to change it!

[Gummiente]

From what you've described it sounds like your clutch may be shot; if the adjuster is all the way out that usually means the clutch plates are worn out and need replacing. There might be another adjuster where the cable enters the engine cases, but you should get a factory repair manual first before adjusting anything to make sure you're doing it right. The heavy lever effort might also be a sign of a rusted cable binding inside its sheath - screw the adjuster all the way in until you can remove the cable from the lever, then squirt some light machine oil into it and allow for it to work its way down. Jiggle the wire cable a few times to see if its loosened up, if not then you'll probably need a new cable.

I'm not familiar with the Katana but if you have to pull the clutch lever in to start the motor then there should be a couple of electrical wires near the lever, these are for a switch that prevents the engine from starting unless it's pulled all the way in. The switch contacts are probably corroded, you might be able to squirt some WD40 in there to fix it or you might have to pull the switch out to fix it.

[BuzZz]

There should be another adjustment ferule in the cable someplace, just a long, hollow threaded bolt-n-nut affair in the cable houseing that you may be able to use to get some adjustment back at the lever. Sounds like the cable needs a good lubing too.

But Duckman may be right about the clutch plates being worn and needing replacement. Try the lube/adjust thing first, and if it don't work it's time to open 'er up.

[Stoeger]

THANKS!!!! Much better! (Not perfect, but better)

I loosened the cable, and unhooked it from lever. Put some oil down it and routed it differently on hookup (ran thru inside of forks instead of outside of forks) and it seemed to be much happier there. Seemed like it was bound up before, this is a more natural curve now.

Voila ~ much easier to pull ~ THANKS!


Now, still have the other problem... clutch still doesn't fully disengage with the lever pulled in, but at least I can pull it back easier now. And much easier to find the sweet spot where it will allow the starter to start. Of course... bike still won't start.. please see my next post... (PLUGS WET AND BLACK)