Clutch lever free play problem

[safetyguy]

My clutch lever is engaging about 1/4 inch off the grip and the lever has a lot of free play in it. Fluid level is OK and the fluid in the reservoir looks clean. (The level was a bit low and some fluid was added about a month ago.)

 

Should I flush it out and rebleed the system to cure the problem? Also, is there a free play adjustment (on the slave cylinder or elsewhere that could have come loose)? I can't find anything in the service manual but maybe I missed it.

 

Has anyone else had this problem?

[yamahamer]

Just bleed it at the slave. It should fix the problem. Use a vacume bleeder if you have one.

[mbrood]

There's no lever adjustment. There's a spring below the small rod that actually engages the lever to the master piston and this should hold the lever out (and engaging the clutch safety switch.

 

with a properly bled clutch, my 86 has about 1/4" of "spring loaded" freeplay before it starts pushing the piston.

 

http://parts.yamaha-motor.com/partimage.gifx?d=12657,6,0

[cmiles3]

I've got the same problem. I was looking at the system and came to the same conclusion; need to bleed it. It's enough play that the cruise control kicks off if I'm riding against a stiff wind, or a truck passes in the other lane.

[woz111]

I'd bleed the clutch if I were you, I had hell bleeding my clutch as it was spongy as hell. I finally put a tube on the bleed nipple to catch the fluid and could see the air bubbles coming through when I was bleeding the system, after a while I finally got a great clutch, it's now as it should be.

[safetyguy]

Thanks -- I'll give it a try and report back.

[rhncue]

Bleeding the master will not always eliminate this problem. The clutch master lever will wear on these bikes if not kept lubricated. The hole in the lever where the bolt goes through for attachment can waller out. Also, there is a brass cylinder that the connecting pin sets into that can become worn. These areas, if worn will allow much play in the lever so as to hinder the proper operation of the master causing the clutch to drag or not fully release when applied.

 

Dick

[Neil86]

yup...part #4 in the diagram....brass bushing....wears out.

[bongobobny]

^^^ Yup!! replaced mine when I rebuilt my master along with part 3. Cheap enough parts...

[safetyguy]

Flushing the fluid did the trick. The junk that came out was pretty sad looking.

 

Amazing how much better it works!!!

[Dano]

Next step would be to pull the slave out and put new seals in there and finish cleaning out the junk. Take an afternoon (rainy day) and you'll be surprised.

 

Dan