How to Install a Clutch Cable on a YZ250

Written by chris gilliland Google
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Your ability to control the clutch is critical to operating your Yamaha YZ250 dirt bike, which relies on the steel cable that connects the clutch lever to the clutch assembly. The extreme conditions found on most motocross tracks or trails can stretch this cable to the point of snapping, effectively cutting off any control over the clutch. Installing a new clutch cable can be done without having to take the bike into a mechanic. Allow a minimum of 15 minutes to complete this task and have a few common tools handy.

Skill level:

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Things you need

  • 10mm combination wrench

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  1. 1

    Insert the barrel end of the clutch cable, identified by the rubber boot at the end of the cable, into the clutch mechanism's catch on the left side of the motor.

  2. 2

    Slip the clutch adjuster on the bottom of the clutch cable into the cable holder, positioned a few inches in front of the clutch mechanism on the motor. Tighten the cable adjuster's locknuts against the cable holder with a 10mm combination wrench.

  3. 3

    Route the clutch cable up the YZ250's frame to the handlebars.

  4. 4

    Slip the rubber clutch lever boot, if the bike is so equipped, over the top end of the clutch cable. Insert the barrel end into the catch on the bottom of the clutch lever. Pull the clutch cable through the channel cut into the clutch lever and its perch until is seated on the clutch adjuster bolt.

  5. 5

    Twist the clutch adjuster bolt clockwise to tighten the cable until the clutch lever can be pulled 1/8 of an inch before it pulls the clutch cable.

Tips and warnings

  • Remove any excess cable slack by using the adjuster on the bottom of the clutch cable. Loosen the adjuster's locknut with the 10mm wrench and turn the cable clockwise to tighten it.

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