Originally Posted by short_fuse
I went through this step by step. The bike seems to be shifting much smoother now. However, the cluth doesn't start to engage until I have the clutch lever out almost all the way. What am I doing wrong?
First off, hat's off to you for working on this yourself.
It is a giant step toward breaking the ice on technical adjustments on your bike. It's also a lesson in why the dealers often do a crappy job of these things...more than one step and a weak mechanic will blow it off and do something easy or nothing at all! You're proving that new to it or not, you're no weak mechanic and that you care how it comes out.
What you're experiencing is due to the combination of all 3 adjustment areas. Most likely is the actual lower adjustment that has the outer locking nut and the center slot adjustment.
1.)Double check the clutch lever adjuster.
The cable's threaded end has to be screwed all the way toward the lever itself, giving just enough room for the circular locknut to be fully threaded and sitting against the stop. This will insure that you have adjustment room after everything is set.
2.) Set the clutch lever free play at the end of the cable housing.
Make sure that you've loosened the lock nut and screw up or down to get the 10-15mm needed at the lever end.
3.) Get that main adjustment.
a.) Make sure that the lock nut is loosened correctly.
b.) Make sure that the center adjuster is backed off correctly and then turned inward till you get resistance, then backed off 1/4 turn.
c.) Check that you've held the center adjuster with a slot screwdrive while you tighten the locking nut. I don't use blue loc-tite here, since it can be tricky to break loose with an adjuster pair like this.
Once you've check all these things, remember that you can leave the covers off while you start the bike and drive it for a moment to get the settings just right. The fact that there are 3 adjustment areas is the reason for the ease with which you can be off a little, but is also the reason you can tweak it in just right, even with a fairly worn clutch.