The following sections included on this page, are for maintenance on the Clutch;

[1] - CHECKING THE CLUTCH OPERATION
[2] - ADJUSTING THE CLUTCH LEVER FREE PLAY
[3] - LUBRICATING THE CLUTCH LEVER
[1] - CHECKING THE CLUTCH OPERATION
© cvvmax December 2013

1. Check:
    • Clutch operation

    If not functional -> Check the clutch system.
Before checking the clutch operation, check the brake system and make sure that the brake is operating at all times during the check-up. While checking the clutch operation, do not rev up the engine.

a. Place the vehicle on a level surface, and start the engine.

b. Grab the clutch lever and make sure that you can shift the gear smoothly.

c. Grab the clutch lever and shift to first gear.

d. Operate both the front and rear brakes, release the clutch lever slowly and make
    sure that the engine stops.
[2] - ADJUSTING THE CLUTCH LEVER FREE PLAY
© cvvmax December 2013

1. Measure:
    • Clutch lever free play "a"
    Out of specification -> Adjust.
Clutch lever free play
5.0-10.0 mm (0.20-0.39 in)

2. Adjust:
    • Clutch lever free play

Clutch lever side
a. Loosen the locknut " 1 "
b. Turn the adjusting bolt "2" in direction "b" or "c" until the specified clutch lever
    free play is obtained.

Direction "b"
Clutch lever free play is increased.

Direction "c"
Clutch lever free play is decreased
c. Tighten the locknut.
If the specified clutch lever free play cannot be obtained on the clutch lever side of
the cable, use the adjusting nut on the crankcase side.

Crankcase side
a. Loosen the locknut " 1 " .
b. Turn the adjusting nut "2" in direction "a" or "b" until the specified clutch lever
     free play is obtained.

Direction "a"
Clutch lever free play is increased.

Direction "b"
Clutch lever free play is decreased.
c. Tighten the locknut to specification.
Clutch cable locknut
7 Nm (0.7 m-kgf, 5.1 ft-lbf)
[3] - LUBRICATING THE CLUTCH LEVER
© cvvmax December 2013

Lubricate the pivoting point and metal-to-metal moving parts of the clutch lever.
Recommended lubricant
Lithium-soap-based grease
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