Clutch adjustment at the lever

Only took me twenty years to try this.

Been riding a few hundred miles with all free play adjusted out of the clutch cable.
Previously, I maintained 3mm +/- free play per FSM, and the lever would constantly vibrate, wiggle and shake while riding.

Now just that tiny amount of lever movement disengages the clutch for smooth-precise shifts, with no slippage under hard acceleration.

It is such a joy to ride...


:woohoo:

Doesn't the free play relieve stress on the inner cable to reduce the chances of the cable end breaking off?

No eBay APP ID and/or Cert ID defined in Kunena configurationNo eBay APP ID and/or Cert ID defined in Kunena configuration

martin_csr wrote: Doesn't the free play relieve stress on the inner cable to reduce the chances of the cable end breaking off?

The tension is relatively light with the lever resting against the perch stop. The lever seems to activate the clutch more smoothly adjusted this way, though the reach is further from the grip.

Am considering elbow shaped levers to shorten the reach:

No eBay APP ID and/or Cert ID defined in Kunena configurationHere’s a set...

Mikaw wrote: Here’s a set...

The brake lever end has to be identical where it fits the master cylinder housing...

martin_csr wrote: Doesn't the free play relieve stress on the inner cable to reduce the chances of the cable end breaking off?

The cold free play of a cable clutch is mainly to allow for heat expansion of the clutch push rod etc
If set too tight the expanding rod and other components can result in zero or negative clearance causing clutch slip.

zed1015 wrote:

martin_csr wrote: Doesn't the free play relieve stress on the inner cable to reduce the chances of the cable end breaking off?

The cold free play is to allow for heat expansion of the clutch push rod etc
If set too tight the expanding rod and other components can result in zero or negative clearance causing clutch slip.

The noted engagement can be felt after the lever is pulled back about a quarter inch while underway. The actual clutch engagement portion of lever movement is a fraction beyond that.

By zed1015: The cold free play of a cable clutch is mainly to allow for heat expansion of the clutch push rod etc
If set too tight the expanding rod and other components can result in zero or negative clearance causing clutch slip.

Thanks. I was thinking the vibrations caused by riding would stress the end of the cable.

If the OP has the lever set to where there is just no free play when cold, as the bike heats up the free play will increase. Depending on the make and material the inner and outer cable are made of, this increase could be substantial or not too bad. On my KZ-1000 with new OEM cables the heat expansion is very noticeable and moves the friction point much closer to the grip. When the bike cools off the friction point moves outward.

Rick H.