Help Zeal Clutch Adjustment

Afternoon fellow Members,

I bought a cheap low km Zeal, it looked pretty complete but was missing quite a few bits required for a Safety Certificate. Managed to find all the parts needed even a headlight cowl assembly sitting in a local wreckers. I have it running sweetly after kitting the carbs etc, found this Forum the best for knowledge and where to get parts etc.

I replaced the clutch plates and adjusted freeplay at the cable and lever but find that the clutch takes up as the lever is near fully out. At the clutch pressure plate I adjusted the screw up gently and then backed it off 1/4 a turn then tightened the lock nut. Any ideas?

 

Thanks for replying, I can but thought more free play might not change where it takes up. I was wondering what the actual spec at the clutch hub was? After tightening number of turns to screw out?

 

Thanks Greyimport,
I have read that thread but doesn’t really give any spec for the adjust screw, I went for 1/4 out before putting the case on which gives some free play at the clutch end before doing cable and lever.

 

I think that’s where I got the spec from, thanks for the access. I found the adjustment but in Japanese

 

Greyimport this is a great forum, in the day of Facebook a forum is still streets ahead in sharing information etc. The bike had been parked up for over 10 years and it being a four cylinder 250 it sparked my interest to save it. Had to do a lot of part cross referencing to find brake parts and the hardest to find was the chain guard. The headlight cowl was on EBay at a local wrecker for $90 need Ed repair work but happy to save it and it works great. Speedo cable is off a TX Yamaha nos from Germany and new flasher lenses from the states.

 

After running the bike on the road now I have given the clutch adjuster 1/2 turn total and seems fine. Barely have to pull the clutch lever in for gear changes.