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Discussion Starter · #1 ·
Firstly I haven't got a Workshop Manual for this bike so I need a bit of guidance.

1) Clutch cable routing - it seems quite short, so I suspect the routing is critical.
2) Clutch adjustment procedure - I fitted the cable temporarily, but can't get the clutch to 'clear'.
With engine stopped and bike on centre stand, if I put bike in first gear and pull clutch lever I cant rotate the back wheel by hand - I expected it to rotate freely. I have adjusted clutch cable but suspect there is some deeper problem. I removed cable and operated lever on crankcase with spanner but cant get clutch to free. Lever moves freely (against the spring) over what I assume is the full distance.

If its allowed, does anyone have a downloadable Manual, or even the section relating to the clutch?
 

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Welcome to the group. PM sent regarding service manual.

More information please. What's the history on the bike? Been riding it every day or has it been sitting a few years?

With wheels on the ground, transmission in gear, clutch lever pulled (clutch dis-engaged), can you push the bike without sliding the rear tire?

Can you turn the rear wheel with the transmission in neutral?

It is also helpful to know your location. Someone near you may be able to help.

Got pictures?
 

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Discussion Starter · #3 ·
Thanks J-T got service manual, excellent quality.
History - just arrived in my garage, previous owner rode in and on to my ramp. Told me clutch biting point was right at the end of the lever's travel ie right out and needs adjusting. He put it down to the wrong length clutch cable being fitted which was effectively too short.
I ordered a new cable from a UK supplier that I trust - David Silver. It arrived today exactly the same length as the one fitted.
Now I have the manual I can see the recommended route which I will follow tomorrow.
I cannot push the bike in gear, without sliding the rear tyre, with clutch disengaged. When in neutral & on the centre stand the rear wheel turns freely.
Looks like something wrong with the release mechanism perhaps?
I am located in Dundee, Scotland, on the east coast 60 miles north of Edinburgh and about the same south of Aberdeen.
No pictures yet, I will have to work out how to get them uploaded.
Thanks & regards.
 

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Discussion Starter · #6 ·
Thanks J_T & longdistancerider. got a bit further with CB250N clutch issues. As you said, with a bit of use steels freed from friction plates and the clutch is smooth, disengaging and engaging. But, there is little or no slack in the cable. Looks like non-standard handlebars have been fitted. They seem longer and slightly higher than the usual UK style. So if that's the case that would explain why overall length of cable seems short. Does anyone know standard length and rise of UK bars for 1981 CB250N?

Also in order to inspect the clutch plates for wear I need a castellated socket. I will make one from a spare socket, does anyone have a drawing?
 

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history - just arrived in my garage, previous owner rode in and on to my ramp.

You know of cmsnl for the exploded views.......

You know of david silver, but do you know of uk based wemoto and M and P and a few others.

I'm all in favour of making your own special tools, I have had to and still do, as I too live in a "desolate area", but sometimes it makes more sense to but one.

See wemoto for the peg spanner.

You know how to make your own bespoke cables soldering on nipples etc., and can get the parts ??

Some specialist cable makers may be able to help.

Whilst the clutch cover is off, take the opportunity to flush out the sump of all the "debris" that will be there including the kick start oil trough. You will now know about the cam chain and balance chain systems and adjustments.

Be aware of grit falling out of oil pressure switch "cavity" onto primary gears.........

your bike or a customers ?
 
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