Tt250 clutch issue

Rockos82 · 03-21-2022, 09:47 PM

Just got a tt250. The clutch is maxed out on the handlebar and on the barrel screw. Does anyone know of a differnt mount to move the barrel screw back further? Thanks.

zero_dgz · 03-21-2022, 10:36 PM

It is also typically adjustable at the other end of the cable, down on the engine case. There will be a lock nut or pair of lock nuts on a threaded section on the end of the cable sleeve. Pro tip: Resist the urge mess with this adjustment when the engine and exhaust is hot. Ask me how I know.

Edit: Disregard, I may have misunderstood your question. If your adjustment is maxed out on BOTH ends, it is also possible that your cable is just hella stretched and requires replacement. However, also make sure that the mount for the cable on the engine case is not installed backwards... On some bikes you can put it on either way around.

Megadan · 03-22-2022, 12:14 AM

Maxed out on both ends and the clutch is still not disengaging? I would agree with the assessment that there is something else mechanical at work. Either a bent mount, stretched cable, damaged cable housing, bent clutch arm, etc.

Does this bike have a lot of miles, or has it been dropped recently?

ChillRider · 03-23-2022, 07:42 AM

Unless this is a brand new bike, the clutch could just be too worn out. Not enough to slip, but enough to run out of adjustment both at the handlebar and down at the engine's barrel screw.

On some bikes you can also reposition the clutch actuation arm, only that you have to remember to reset it once you do install new clutch plates/friction disks.

Megadan · 03-23-2022, 04:12 PM

Quote:

Originally Posted by ChillRider

Unless this is a brand new bike, the clutch could just be too worn out. Not enough to slip, but enough to run out of adjustment both at the handlebar and down at the engine's barrel screw.

On some bikes you can also reposition the clutch actuation arm, only that you have to remember to reset it once you do install new clutch plates/friction disks.

Also a good point. I was under the assumption that he just got a new one. He could have just got somebody else's beat up used one.

ChillRider · 03-24-2022, 04:10 AM

I've found out about the clutch wear scenario on my Zongshen Sierra: for the last couple of months I need to adjust the clutch every so often. After an oil change the feeling is much better, but once the engine gets hot (esp. from city driving) there is excessive slack/clutch drag. With long highway rides there's virtually no issue.

I also replaced the clutch cable, just in case the old one had stretched, "robbing" me of some adjustment length. Well, it did, but it was like 5mm at the most. So that "bought" me only enough play so the lever adjuster doesn't hang by a single thread, but the barrel one is still maxed out. I already ordered all necessary parts (plates, fibers, gaskets etc.) and will perform the job myself one the clutch becomes unadjustable.

IDEA: speaking of level adusters, it might be possible to fabricate a longer bolt by drilling a guide and slot. Of course that's a stopgap solution, also to be replaced when a proper clutch service is performed.

03-21-2022, 09:47 PM	#1
Rockos82 Join Date: Mar 2022 Posts: 1	Tt250 clutch issue Just got a tt250. The clutch is maxed out on the handlebar and on the barrel screw. Does anyone know of a differnt mount to move the barrel screw back further? Thanks.
	0

03-22-2022, 12:14 AM	#3
Megadan Join Date: Apr 2017 Location: Omaha, NE Posts: 8,045	Maxed out on both ends and the clutch is still not disengaging? I would agree with the assessment that there is something else mechanical at work. Either a bent mount, stretched cable, damaged cable housing, bent clutch arm, etc. Does this bike have a lot of miles, or has it been dropped recently? __________________ Hawk Information and Resource guide: http://www.chinariders.net/showthread.php?t=20331 2018 Hawk 250 - Full Mod list here. http://www.chinariders.net/showpost....62&postcount=1 2024 Royal Enfield Shotgun 650 https://chinariders.net/showthread.php?t=34124
	0

03-21-2022, 10:36 PM	#2
zero_dgz Join Date: Jan 2020 Posts: 257	It is also typically adjustable at the other end of the cable, down on the engine case. There will be a lock nut or pair of lock nuts on a threaded section on the end of the cable sleeve. Pro tip: Resist the urge mess with this adjustment when the engine and exhaust is hot. Ask me how I know. Edit: Disregard, I may have misunderstood your question. If your adjustment is maxed out on BOTH ends, it is also possible that your cable is just hella stretched and requires replacement. However, also make sure that the mount for the cable on the engine case is not installed backwards... On some bikes you can put it on either way around.
	0

03-23-2022, 07:42 AM	#4
ChillRider Join Date: Jun 2020 Location: A small country with a funny name Posts: 164	Unless this is a brand new bike, the clutch could just be too worn out. Not enough to slip, but enough to run out of adjustment both at the handlebar and down at the engine's barrel screw. On some bikes you can also reposition the clutch actuation arm, only that you have to remember to reset it once you do install new clutch plates/friction disks.
	1

03-24-2022, 04:10 AM	#6
ChillRider Join Date: Jun 2020 Location: A small country with a funny name Posts: 164	I've found out about the clutch wear scenario on my Zongshen Sierra: for the last couple of months I need to adjust the clutch every so often. After an oil change the feeling is much better, but once the engine gets hot (esp. from city driving) there is excessive slack/clutch drag. With long highway rides there's virtually no issue. I also replaced the clutch cable, just in case the old one had stretched, "robbing" me of some adjustment length. Well, it did, but it was like 5mm at the most. So that "bought" me only enough play so the lever adjuster doesn't hang by a single thread, but the barrel one is still maxed out. I already ordered all necessary parts (plates, fibers, gaskets etc.) and will perform the job myself one the clutch becomes unadjustable. IDEA: speaking of level adusters, it might be possible to fabricate a longer bolt by drilling a guide and slot. Of course that's a stopgap solution, also to be replaced when a proper clutch service is performed.
	0