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Discussion Starter #1 (Edited)
I've got a question for you all.
I just swapped my clutch, and I'm second guessing my freeplay adjustment, I need some clarification from those in the know.

My Haynes manual had 10-15mm freeplay until I "feel resistance", it's the resistance in asking about.

Is the freeplay supposed to be the amount of any/all slack in the cable?; or is it supposed to be once the "real" resistance is felt from the clutch springs?

At first I tried doing it as the freeplay accounting for additional slack in the line from any form of even the slightest resistance. In other words, if I release the clutch slowly enough, the lever will always have that small v shaped gap between the lever and the perch and never go all the way forward unless pushed forward. The problem is, when I do it that way, the gears are a beotch to shift. Very hard and it's almost like forcing the shifts. Almost impossible to find neutral. So I'm thinking that's not right.

When, on the other hand I adjust it so that is 10-15mm of slight resistance before you feel the resistance from the springs engaging; well then it shifts beautifully, finding neutral is not (as much of)a chore. My only concern is that if I eliminated too much freeplay that I might burn out the new clutch.

Not sure if it matters but I do have a clever lever on it. (Not sure if the geometry affects how much freeplay one should have).

For what is worth, the spring engagement point is right when the arrow meets the center of the dot, if I let the line go slack it stops around the righthand most outer circumference of the dot. (I'm taking about the arrow and dot at the end of the clutch cable).

I know this is a fairly rudimentary question, but I just want to get it right before I do some major damage.

(Almost forgot 1999 650 classic, 65K miles)
 

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there is adjustment at the rod. at the top and bottom of the cable. the adjustment for the rod is on the clutch pressure plate



check page 3-19 in the factory repair manual for clutch cable and 4-41 for clutch pressure plate
 
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