I've been adjusting my own clutch and performing the 2,500mi maintanence on my own bike for the past 12 service intervals. The last time I did so was the first time that I turned the clutch screw to resistance and it didn't end up right back where it started when I backed it off a 1/4". Since that last adjustment I've been having all kinds of trouble with the clutch/clutch lever. I've adjusted the clutch cable 6 times and it just seems like the action keeps changing. It is fine and then it sticks (not all the time, but maybe 20% of gear shifts), b/c it was sticking I thought maybe the cable needed lubricant. Lubricated the cable, it was fine. 50 miles later, I can't get the thing in neutral. Adjusted the cable again, it was fine. 50 miles later, the lever isn't returning to normal position on its own. Adjust the cable again, 50 miles later the gears aren't shifting smoothly and the shift lever feels crunchy. I'm on the way home from work, get pissed because it isn't shifting right again and when I get home pull the derby cover, adjust the clutch screw again. Tighten the cable back up, ride it a couple of miles and everything is fine. Let it sit overnight, get on it this morning - start the bike, pull the clutch lever, push it into 1st and it tries to run out from under me. Go down the road, HARD to shift into second, HARD to shift into third. Can't get neutral without shutting it off. While it is off, I adjust the cable again... Nothing changes. I'm thinking that the clutch is shot. It does better (at some times just fine) when it is hot. The fact that the action keeps changing has got me baffled. I'll shift without issue eight times and then all of a sudden the cable hangs up and the lever doesn't return to normal position on the ninth shift. Is it possible that I've got the clutch adjustment screw all kinds of $%#*ed or is the clutch just done for? The bike is a 2008, 51K... original clutch. Thanks!

 

12 service intervals? You have some milage racked up, good for you! Plate and spring inspection time. An easy swap if they're shot.

 

Make sure you are adjusting the clutch when the bike is cool not after riding it!

 

It was hot, hot, hot when I did it yesterday... maybe that's where the problem came in. It will be cool when I look at it tonight... Thanks! Didn't realize that it made any difference...

 

I would also back the adjustment out 1/2 to 3/4 turn, not 1/4 turn.

 

Make sure the circlip is seated properly in front of the presure plate of the clutch. Use a screw driver and a hammer to tap it to make sure it is completely seated.