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BCrider.com Buell Blast clutch cable adjustment project

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Buell Blast


Clutch/Cable Adjustment

It is normal for a clutch cable to periodically need readjustment.
Check for proper adjustment at regular intervals.
(About every 8,000 km/5,000 mi)

To do a proper adjustment first the clutch should be adjusted and then the clutch cable.


Prior to adjusting the clutch:

  • Disconnect and remove battery

  • Support and raise rear wheel

  • Remove left foot peg bracket
    Refer to Blast Transmission page for instruction


Tools required to adjust clutch/cable:

9/16" open end wrench and 9/16" socket & ratchet
1/2 " open end wrench
#27 Torx bit / driver
Slotted screwdriver



Buell Blast - removing clutch inspection cover. - Click photo to enlarge

 

Adjusting the Clutch

Remove clutch inspection cover using #27 Torx bit.

( Remove left foot peg assembly to access clutch inspection cover)


Buell Blast showing how to loosen lock nut to adjust clutch cable. - Click photo to enlarge

Slide rubber boot to expose cable adjuster.

Use 9/16" wrench to loosen lock nut.

Turn adjuster with the 1/2" wrench to shorten cable, ensuring a large amount freeplay at the clutch lever.

Buell Blast - clutch cable lever. Read about how to adjust the clutch cable... - Click photo to enlarge

 

 

 

 

 

 

To adjust clutch mechanism remove spring and hex plate, turn adjusting screw counterclockwise until it lightly seats. Turn adjusting screw clockwise 1/4 turn, reinstall hex plate and spring.

Buell Blast clutch adjustment showing hex plate and spring.  -  Click photo to enlargeBuell Blast clutch adjustment screw. -  Click photo to enlarge

 

 

 

 

 

 

 

At this point you want to take out most of the slack in clutch cable. Then seat the clutch mechanism by squeezing the clutch lever a few times.


Buell Blast showing how to loosen lock nut to adjust clutch cable. - Click photo to enlarge

 

Adjusting the Clutch Cable

Turn adjuster to lengthen the cable so that there is a little freeplay in the clutch lever (about 1/8").

 

Buell Blast, showing 1/8 inch freeplay in clutch lever - Click photo to enlarge

 

 

 

 

 


NOTE: What you want to achieve is a clutch that isn't dragging when the lever is pulled in and not slipping when lever is fully released.


 

Replacing the Clutch Cable

If your Buell has a lot of miles on it you may want to consider replacing the clutch cable.

Buell Blast - clutch cable clamp at the lower front motor mount - Click to enlargeBuell Blast - removing clutch cable clamp at lower motor mount - Click photo to enlarge

 

Ensure there is slack in the cable.

Remove cable clamp at the lower front engine mount.

 

 

Replace the clutch cable by unhooking the cable end from the ramp adjuster mechanism. Then remove the fitting at the primary cover.

 

Buell Blast - adjusting clutch cable. - Click photo to enlargeBuell Blast - clutch cable lever. Read about how to adjust the clutch cable... - Click photo to enlarge

 

 

 

 

 

 

At the handlebar remove cable end from clutch lever.

 

Install new cable:
Buell Blast - take care not to cross-thread the new clutch cable fitting upon replacement - Click photo to enlarge

Remember to replace the O-ring. Thread the new cable into the primary housing, taking care not to cross-thread the cable fitting into the primary cover.

Attach cable end to clutch mechanism. Route cable to the clutch lever and reattach. Reinstall cable clamp at the engine mount.

Now follow Cable Adjustment procedure as stated above.

 

get info on Buell motorcycles including S3 and Blast

 

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