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Help Adjust clutch on ZZR250

Discussion in 'Kawasaki 250cc Twins' started by jazzhunt, Apr 12, 2015.

  1. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    My newly acquired ZZR250 drives the rear wheel when it's in gear, whether the clutch is pulled in or not. I've googled clutch cable adjustment and watched a couple of youtube vids but no-one seems to say which direction I need to move the bottom adjustment to overcome this problem.
    Frankly, I've tried both ways without success but I'm curious about which way I should be adjusting it.
    Should I be aiming to see more of the threaded adjuster above the fixed tube or should more threaded cable be visible closer to the gearbox?
    Any tips or suggestions would be appreciated.
     
  2. Joker

    Joker If you want me find Club250 on facebook. Premium Member Contributing Member

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    It sounds like your clutch cable is too tight. Post up a photo of the clutch lever where the cable goes in. I'd say screw it in further until the problem subsides. If it's all the way in and it's no different you'll probably need a new cable. They're not expensive, $15 or so by memory. Been a few years since I had mine.
     
  3. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    Yeah, I think you're right Stu, I have now tried it at both ends of the scale three times and it's made no difference. I think it's time for a new cable. Still, it's not the worst problem you can have with a new toy :)
     
  4. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    you have a cable with a built in adjuster on the RH side engine cover near where you fill the oil which lengthens and shortens the cable as needs be , the adjuster on the clutch lever is for fine adjustment and there should be 2-3mm of free play in the lever if its set correctly

    Capture.PNG
     
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  5. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    Thanks Kiffsta, that's where I have been doing the adjustments and whether I screw it up all the way or down all the way (plus adjusting the lever as necessary to maintain a 2-ish mm gap up there) the problem doesn't go away. I thought I'd go to each end of the adjustment range until pulling the lever 'disconnected' the drive and then wind it back until the clutch 'bit' again but no matter how far I go as soon as I drop it into gear the wheel starts turning, despite holding the lever in. If I return back to neutral the wheel stops spinning.
     
  6. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Your clutch plates are stuck together and no amount of adjustment will help until you un-stuck them. Try putting bike into gear without motor running, hold clutch lever in rock back and forwards until you feel clutch release. Another method is to ride slowly with bike in first gear holding the clutch lever in and accelerate and decelerate until the plates release.
    Once you have freed the plates, them adjust cable as per manual. Good luck.
     
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  7. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    And have u changed the oil ? .... they are a wet clutch
     
  8. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    Murdo, I reckon you're on a winner :) When I follow your suggestion I can feel it let go or, at least, I can wheel her around with the clutch in where I couldn't move it at first. Mind you, as soon as I stop the problem returns. Still, I think you might be right and, if I understand this problem properly, some regular rides might help. I have only just bought this from a dealer and I know it had been sitting there for some months so that might be the origin of the problem. Next chance I get I'll take it for a long run and see what happens. GreyImport, no, I haven't done an oil change, dealer might have (or not!). Do you think doing one now-ish might help?
     
  9. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Would certainly help. Use proper motorbike oil and with some riding it should be fine.
     
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  10. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  11. Phil

    Phil Senior Member Premium Member Contributing Member

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    Just reading your comments, if you purchased the bike from a dealer I would be on the blower now and get them to remedy your clutch problem.....and whilst at it ask wether an oil change was done prior to sale.
    You have rights, use them......keep us posted.
     
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  12. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    Thanks Phil. A mate of mine from work (he's an engineer and ex-factory mechanic) took the bike out for me today and fixed it. He tells me he didn't do anything other than ride it and adjust the cable back to where it had been but, whatever, problem is fixed :) Thanks to everyone for your tips and advice.
     
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    Last edited: Apr 13, 2015
  13. TechHeadFred

    TechHeadFred Well-Known Member

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    You've reminded me I need to adjust the clutch on Nix (my ZZ-R250) as I haven't set it properly since I replaced the left clip-on.
    I think I've just adjusted my riding style accordingly though - it's my daily commuting bike and I haven't done any work on it at all since repairing crash damage to get it back on the road!
     
  14. jazzhunt

    jazzhunt Well-Known Member Premium Member

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    Lol, I'm glad I could help Fred :)
     
  15. Phteven

    Phteven Member

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    Hi, i have recently started riding have a zzr250 with the same problem and i have to do this each time i start the bike. Are the clutch plates supposed to stick together like this or should the free up straight away on their own? If they are supposed to be free is there a way to resolve the problem?

    I have replaced the oil and filter since i bought the bike and used proper motorcycle oil.

    Sent from my SM-G950F using Tapatalk
     
  16. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Try murdo's suggestions along with revving the bike a bit in neutral. Maybe pour a tad of fresh oil into the clutch plates via the oil filler as well.

    Of course the proper way to fix it is to take the clutch cover off, take the plates out and soak them in oil for a few hours or even over night.
     
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  17. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    ... and check they are in good condition and installed correctly
     
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  18. Phteven

    Phteven Member

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    This is something i cant do. I dont know much about how they should be. Condition would be easy enough, chech for material thinkness and scoring.

    Sent from my SM-G950F using Tapatalk
     

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