Trying to lube a clutch cable on an 09 klx 250s

[UnbForester05]

Hi guys looking for some insight. Today I wanted to do a bit of winter maintenance and lube the clutch cable on the klx. I began by loosening the locknut by the lever housing and turning the adjusting screw fully in toward the housing. This slackened the cable somewhat.

The problem I'm having is pulling out the sheath from the end of the adjuster so that I can free the remainder of the cable from the clutch lever. There still is not quite enough slack to free things up even with the adjuster as far in as it will go. So my question for you guys is

a) should I just remove the clutch lever from the perch and free the cable once the lever is loose or

b) Do I need to further slacken the cable using the adjusting nut lower down on the clutch cable housing (middle of cable). If yes, how do I loosen this?

Note that I do have aftermarket bars on so these may be making things a tad tighter. Not sure though.

Pretty frustrating as I figured this would be a dead simple job. Had to walk away from it tonight as I have a habit of loosing my temper with things like this. Any help would be appreciated. Thanks guys. Oh the joy of being new to bikes. lol.
:hb:

 

[Sparkle]

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Hi UBF:

The adjustment on the lever perch is set more to take up slack rather than loosen the cable. The main clutch adjustment is at the engine clutch actuator lever. This is a threaded tube with a locknut.Loosen the locknut and turn the threaded shaft in.Between the main adjuster and the lever adjustment you should have all the slack you need.

The middle adjuster is just to provide extrarange if you need it...I don't normally change this on my bike. It is just two tubes....one threaded into the other with a lock nut to keep them from unthreading. Loosen the middle locknut and thread the tubes together to loosen the cable.

When re-setting the cable, make sure the lever adjustment is screwed in as far as it can go, then adjust the main clutch adjuster until it takes up most of the slack....then use the lever adjustment to fine tune. Check your manual for free-play. I usually let my clutch lever have about 1/4 to 3/8 inch of slack at the ball-end of the clutch lever.

Some clutch cables are teflon lined and lubrication isn't recommended.

Sparkle

 

[UnbForester05]

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Thanks Sparkle, I'll give that a try this weekend. Cheers:hb:

 

[Mad Max]

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Don,t take it apart.Just lay the bike on its side and pull your clutch in and out as you lube it.Lazy but it works.

Max

 

[old trials guy]

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There is no substitute for one of these:





I have used one of these for years and they work great. You can actually see the lube come out the other end of the cable so you know you have it fully lubed.

These are so cheap and work so good there is no reason not to have one in your toolbox. I use the cable spray lube that came with it and it works good too. Cables last longer and work like new.

Thegrommet is stepped on the inside to accomodate different cable housing diameters but you need to leave some clearance inside when clamping on the cable so there is room for the lube to flow into the cable inner.

otg

 

[UnbForester05]

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Thanks for the info OTG.. Actually bought one of those the other day. Gonna try the "Cable Life" kit. Comes with the housing to clamp on the cable and a can of lube. Getting closer to biking season everday! Whoooooo! :hb: