Clutch adjustment issue

[JacobJ265@gmail.co]

Ok so this is hard to describe. But I just got this bike. It's my first bike but not my first manual gearbox. Anyway, the bike is a 2017 like new with only 3900 miles. The guy put aftermarket levers on it. Well, when riding it doesn't shift as smoothly as I would expect.. you have to press a little hard and sometimes it clicks up and feels like it's clicking half way then it will click the rest of the way. Same with down shifting. No harsh noises when this happens just wierd. so I start inspecting and making small adjustments(at the lever) but nothing changed really. Then I noticed where the clutch cable attaches to the clutch arm on top of the clutch casing. There's a little dot on the outside of that arm. And just below that on the clutch casing there is a little arrow. So I start thinking well these should be in line with each other. They were very close but not perfect. So I adjusted the line until it was perfect. It took all of the "free play" out of the clutch lever but I decided to take it for a quick spin up the street to see what happened. The shifting was ABSOLUTELY butter smooth. Shifting up, down, and finding neutral became easier from 2nd and 1st. BUT, I noticed some noise coming from the gearbox area of the motor. Doesn't really sound like a knocking noise. It's hard to describe just a slight super fast paced click. Or almost like springs being shaken around in a wooden box. So idk what to do because it shifted sooooo much better. But I'm concerned about the sound. Has anyone else encountered this. FYI the engine was pretty toasty, around 205 or 210 I haven't tried running it cool yet. Any info at all is appreciated. Thanks.

Edited September 28, 2021 by JacobJ265@gmail.co

[JacobJ265@gmail.co]

1 hour ago, JacobJ265@gmail.co said:

Ok so this is hard to describe. But I just got this bike. It's my first bike but not my first manual gearbox. Anyway, the bike is a 2017 like new with only 3900 miles. The guy put aftermarket levers on it. Well, when riding it doesn't shift as smoothly as I would expect.. you have to press a little hard and sometimes it clicks up and feels like it's clicking half way then it will click the rest of the way. Same with down shifting. No harsh noises when this happens just wierd. so I start inspecting and making small adjustments(at the lever) but nothing changed really. Then I noticed where the clutch cable attaches to the clutch arm on top of the clutch casing. There's a little dot on the outside of that arm. And just below that on the clutch casing there is a little arrow. So I start thinking well these should be in line with each other. They were very close but not perfect. So I adjusted the line until it was perfect. It took all of the "free play" out of the clutch lever but I decided to take it for a quick spin up the street to see what happened. The shifting was ABSOLUTELY butter smooth. Shifting up, down, and finding neutral became easier from 2nd and 1st. BUT, I noticed some noise coming from the gearbox area of the motor. Doesn't really sound like a knocking noise. It's hard to describe just a slight super fast paced click. Or almost like springs being shaken around in a wooden box. So idk what to do because it shifted sooooo much better. But I'm concerned about the sound. Has anyone else encountered this. FYI the engine was pretty toasty, around 205 or 210 I haven't tried running it cool yet. Any info at all is appreciated. Thanks.

Edit: at the clutch arm on top of the clutch case there is play in the arm. If I push all that play out the dots are lined up. Should I take that play out at the clutch arm so the dots are lined up and then adjust my free play to factory spec and try that.

[longrider1951]

Make sure you have at least 1/8" free play at the clutch lever. You can adjust it at the lever using the thumb wheel and it shouldn't effect anything at the clutch arm. Hope this helps.