How much play should there be in the clutch lever while riding? It seems that when I put the bike in gear, the lever doesn't extend all the way out. I can actually push it out another quarter inch or so. The clutch grabs closely to the grip so I am thinking that I can adjust the the levers play a tad. How difficult is this. Yes, I know, I am going to get a manual. I plan on riding to the dealer, about 40 miles from me, tomorrow but I think I might to try this befor actually going. Any help would be great. Thanks in advance.

 

1.6 to 3mm freeplay. Aka about a 16th of an inch cold. Best place to measure is at the cable ferrule.

 

You have a little excess. Just need to extend clutch cable by breaking the locknut and screwing it apart to make outer sheath longer. However, you need the adjustment correct at the clutch itself. This requires you to remove derby cover and with an allen wrench hold it and break the clutch locknut and make sure the clearance is correct there. Then you adjust cable free play. The clutch free play once set should remain the same for quite a while. I usually set my 1/2" turn of free play. Wear makes this greater so you are OK. Do not do less since heat reduces it and if you do not have enough clutch may slip or spin throw out bearing all the time I give the cable play about 1/16" checked both sides of lock to lock of the bars. This way you have plenty of clutch break and engagement start sooner as you release lever.

 

Whatever you do, do not remove all of the slack in the lever. 1/4" does not sound excessive at all to me. If anything, that's pretty close to the minimum I'd ever want to see. If you remove all of the freeplay you will be risking clutch slippage and accelerated wear.

Just for a point of reference, my clutch and cable is adjusted so I have approx 1" of freeplay (3/4" cold - 1 1/4" hot) measured at the tip of the lever. This provides me with clutch engagement immediately off the grip which is where I prefer it. It does make nuetral a little tough to find at times but that's a worthy trade-off for me.

 

I would like mine to release close to the bars as well. How do you set your clutch adjust at the primary?

 

You can accomplish the same thing and still have the lever fully retract if you give it a little more play at the clutch basket.

My wife has small hands and I had to do this with her Dyna so clutch engagement was closer to the grip like yours. Her problem was it was hard for her to work the friction zone as the clutch engaged past the reach of her hands........lol

 

The lever free play is measured up at the stop shoulder were the cable hooks to it. It really is with the lever held fixed and you grab the outer sheath and pull back and forth and observe the free play in it. Is the 1" of free play you refer to at the tip the end of the lever were it hangs out of your palm?

 

Will keep this simple do not just adjust cable free play only you are due for a clutch adjustment.
Here you go any question ask you will get plenty of help.
If you want clutch to engage sooner go 3/4 turn if you like a longer travel go 1/2.

 

That's good to hear 2black, cuz I would run out of adjuster threads if I had to adjust the ferruel as close as the manual calls for. I'm doing good with 1/4-3/8".

 

I adjust inside the cover to 1 full turn, then adjust the cable to provide the desired engagement point. I pay absolutely no attention to the 1/16" to 1/8" at the ferrule that is specified in the manual.

Not on either of my bikes. I go a full turn inside the cover and if I adjust the cable as specified the engagement point is way too far from the grip for my liking. And... You don't want the lever to fully retract. You need some freeplay to ensure full clutch engagement.

I'm perfectly aware of the specified adjustment procedure. What I'm saying is that the specified procedure will not result in the clutch "feel" that I prefer. The specified adjustment procedure results in an engagement point farther from the grip than I prefer. And yes the 1" I'm talking about is at the tip of the lever as you described.