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I tried searching for this when I was having this issue but didn’t find a thread on it. So I figured I would share what I did.

So a few weeks ago I replaced my old OEM bars, OEM risers and OEM levers and perch’s. I stayed OEM on the bars just did a new set, and went aftermarket on the risers and levers and what not.

Well somehow even though the risers were the same amount of rise, I had way too much free play in the clutch cable. Even after doing a proper clutch adjustment, and adjusting the free play adjuster at the lever (had it out all the way, held in by 3 threads!) I still had about an inch of free play.

What I did to resolve the problem was take an old tire pressure gauge and cut it down to 1/2” and slipped it on the end of the clutch cable where it goes into the case. The tire pressure gauge tube is the perfect diameter and still looks chrome/shiny to look somewhat good.

Then I readjusted the clutch at the case and at the lever. Now with my free play adjuster almost screwed in all the way, I have the perfect amount of free play that I like (which is next to none!)
 

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Super Moderator "Loose Nut"
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5,101 Posts
Nice work around. I resently replaced my throttle cable with after market and had same issue. A couple of small washers on the throttle body side cable end was my fix.
 

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Nice idea on taking out the play in your clutch cable. I have the same problem with a 2013 VStar 250. If I adjust the free play out of the cable the clutch then catches too far out. My setup is different than yours but the problem is the same. You have given me enough encouragement to get creative. Thanks, Slowlane
 
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