Author Topic: Correct clutch lever freeplay  (Read 1285 times)

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  • Online 3alfa3   hr

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    Online 3alfa3

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    Correct clutch lever freeplay
    on: Jun 05, 2022, 03.05 pm
    Jun 05, 2022, 03.05 pm
    OK, so, Manual states its between 2-3mm. I always used 3mm (never had clutch slippage in 42.500km on Z900 or any other bike i had).


    But, years (decades) ago,  i found a simple check if freeplay is enough.....
    If you can feel at least minimal freeplay when accelerating wide open throttle in 6th gear in midrange revs for few seconds (uphill preferably) and check the Lever for freeplay (it will be smaller compared to when Engine is not loaded), that is enough. If you cant feel any freeplay, it is to small, just add it untill you can feel it in that scenario.


    Of course, if for some reason you want bigger freeplay, go ahead, no harm for clutch in doing so as long as it disengage fully when lever is pulled
    Last Edit: Jun 05, 2022, 03.14 pm by 3alfa3

  • Offline MaverickAus   au

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    Offline MaverickAus

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    Re: Correct clutch lever freeplay
    Reply #1 on: Jun 06, 2022, 09.07 am
    Jun 06, 2022, 09.07 am
    I'll stick to the specs in the book

  • Online 3alfa3   hr

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    Online 3alfa3

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    Re: Correct clutch lever freeplay
    Reply #2 on: Jun 06, 2022, 11.38 am
    Jun 06, 2022, 11.38 am
    *Originally Posted by MaverickAus [+]
    I'll stick to the specs in the book

    If you do that, you WILL have that slack when hard acceleranting in 6th gear, especially if that slack is 3mm when bike rests.  :028:


    There's so many fried clutches on this Forum, so tried to give another way of telling if slack is to small: slack gets smaller when clutch is loaded by engine when riding.
    Last Edit: Jun 06, 2022, 11.41 am by 3alfa3

  • Offline rcannon409   us

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    Offline rcannon409

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    Re: Correct clutch lever freeplay
    Reply #3 on: Jun 08, 2022, 02.48 pm
    Jun 08, 2022, 02.48 pm
    When clutch plates get hot, the thickness increases.  This is why you need the Freeplay in the cable. 

    Don't obsess about it.  It's a lot like adjusting a chain.  A little too loose is no big deal.  The only thing that would happen is you have too much is you would not be able to open the clutch as much as it's supposed to open.  You might feel your bike trying to creep forward , I gear, with the lever pulled in.  You might  also feel  like shifting is more difficult.

    Too little Freeplay will burn the plates as they slip.

  • Offline Bentham   gb

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    Re: Correct clutch lever freeplay
    Reply #4 on: Jun 08, 2022, 08.05 pm
    Jun 08, 2022, 08.05 pm
    As we are discussing clutch mattersÖÖÖ

    One thing Iíve found unusual on the z900 is Iíve had to slacken the clutch cable as the miles have gone up. Iím now over 3 years & 23000 miles. I suppose the friction plates may have expanded slightly with oil absorption? Sounds mad I know.
    I first realised it was tighter when my lower gear changes became more jerky as Iíd lost the free play at the end of lever travel.
    Also, I never noticed the squeaky clutch until it was around 2 years old.

  • Offline zed9   us

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    Re: Correct clutch lever freeplay
    Reply #5 on: Jun 09, 2022, 01.02 pm
    Jun 09, 2022, 01.02 pm
    I adjust the clutch lever based on the free play at the actuator lever on the engine. With the hand lever fully released, the small actuator lever (or whatever itís called) at the engine should be able to be wiggled a little by your fingers. Just a little so you know the cable isnít pulling on it.

  • Offline rcannon409   us

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    Offline rcannon409

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    Re: Correct clutch lever freeplay
    Reply #6 on: Jun 09, 2022, 02.39 pm
    Jun 09, 2022, 02.39 pm
    Zed, that's the best way.  Probably the easiest, too since it eliminates the possibility of someone confusing lever play for what we are really trying to achieve

  • Offline zed9   us

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    Offline zed9

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    Re: Correct clutch lever freeplay
    Reply #7 on: Jun 09, 2022, 05.45 pm
    Jun 09, 2022, 05.45 pm
    That lower lever is called the "release lever".
    I just wiggled mine (😝), the cable is slightly loose as is the lever.
    Perfect.

     



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