ES250/2 clutch adjustment

[Michael Jennings]

Hello,

I assembled the clutch on the bike about a year ago and when I pull the lever, it feels like the clutch is actuating i.e. it moves against spring pressure but it’s not releasing. It has about 1/8″ free play on the cable. With the small cover off, should anything visible be moving as the clutch lever is pulled? I hear that the plates can stick together, so is there any way of freeing them without stripping the clutch?

Cheers, Mike Jennings

[Michael Jennings]

On further checking, kicking the engine over with the clutch pulled in frees the engine from the kickstart, so the clutch seems to be working. On the other hand, when I pull the clutch in , place the bike in gear and then push it, the clutch does not disconnect the engine from the rear wheel. So the clutch does not seem to be sticking, but it won’t disconnect the engine from the rear wheel when the bike is in gear.

[Derek Reynolds]

In general, I would be inclined to think that part of the clutch is still sticking. I would be looking to remove the primary case cover, and observe what was happening within when the kickstart is operated out of gear with clutch lever pulled in; what is happening when the clutch lever is released; and the same when a gear is selected.

[Andrew James]

Sounds like there is not a lot wrong and the clutch is just suffering from standing. I suspect the clutch may free up with a bit of running so you could

temporarily take up the 1/8 slack at the leaver which will lift the plates slightly more

kick it over a good few times with the clutch pulled in

put the bike on its centre stand and make sure the back wheel is off the ground. Then start it up run it a few minutes with the clutch in to spread the oil and then slip it in gear but keep the clutch in too. The back wheel will probably spin but a few dabs on the back brake may let you run the bike clutch in, in gear and rear wheel stationary. This will warm the clutch and may free it up without stripping and cleaning.

Let us know how you get on

Hope this helps, Andy

[Michael Jennings]

Hello,

many thanks for the tips – I’ll have a go,

Cheers, Mike

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