RMZ250k4 CLUTCH RELEASE LEVER POSITION ADJ.

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Apr 30, 2001
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#1
Got Anouther Bulletin If The Clutch Release Lever Is Inthe Wrong Position Clutch Slipage Or Insufficent Clutch Disengagement Could Occur. Ok This Is The Lever Comming Out Of The Engine Where The Cable Hooks On. From The Cable End At The Ball To The Cable Holding Bracket It Should Measure 36.7 To 44.5 With This Measurement You Should Run A 1.5 M.m. Washer Between Clutch Thrust Washer And Pressure Plate. More Than 44.5 Shim It Using 1.0mm Less Than 36.7 Use Qty. 2. 1.0mm Shims. Between Pressure Plate + Thrust Bearing. Understand That This Is Not A Warrenty Problem With New Bikes. Just Info. To Help Fine Tune Your Assembly For Proper Clutch Operation. If You Are Not Sure Ck With Your Local Suzuki Shop They Have The Bulletin # Rm-z No.2
 
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Jul 13, 2000
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#2
Clutch lever position

zuki dave said:
Got Anouther Bulletin If The Clutch Release Lever Is Inthe Wrong Position Clutch Slipage Or Insufficent Clutch Disengagement Could Occur. Ok This Is The Lever Comming Out Of The Engine Where The Cable Hooks On. From The Cable End At The Ball To The Cable Holding Bracket It Should Measure 36.7 To 44.5 With This Measurement You Should Run A 1.5 M.m. Washer Between Clutch Thrust Washer And Pressure Plate. More Than 44.5 Shim It Using 1.0mm Less Than 36.7 Use Qty. 2. 1.0mm Shims. Between Pressure Plate + Thrust Bearing. Understand That This Is Not A Warrenty Problem With New Bikes. Just Info. To Help Fine Tune Your Assembly For Proper Clutch Operation. If You Are Not Sure Ck With Your Local Suzuki Shop They Have The Bulletin # Rm-z No.2
 
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#3
Dave,

Can you be more specific in how to measure the distance?Is it from the end of the cable where it enters the iron ball or at the end of the ball (=4mm further)or at the outside of the lever (=again 2mm further)The other measuring point ,I suppose,is the side of the cable holder facing the rear wheel and not the front wheel side?
 
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#4
i no it,s tough to exsplain that every body will know. the end of the cable where it meets the ball. + front side of bracket. also part # on washers 1.5mm k9220-01548. + k9220-00045 1.0mm washer. if not sure see local shop get a copy.the picture will help you understand. just not computer savy enough to down load picture yet. thanks. reference to page 6-11 6-12 + 6-13 of service manuel. also push lightly on lever arm while taking measurement.
 

lavaman

Back 2 riding 2-Strokes
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Sep 21, 2003
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#5
zuki dave said:
i no it,s tough to exsplain that every body will know. the end of the cable where it meets the ball. + front side of bracket. also part # on washers 1.5mm k9220-01548. + k9220-00045 1.0mm washer. if not sure see local shop get a copy.the picture will help you understand. just not computer savy enough to down load picture yet. thanks. reference to page 6-11 6-12 + 6-13 of service manuel. also push lightly on lever arm while taking measurement.
Are ya supposed to push the arm lightly toward the rear wheel while taking measurement???