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Checking the Installed Gap
The installed gap can be checked at any time by verifying the
free play gain
. Checking for free
play gain at the start of each ride is quick, easy and ensures the clutch plates will become fully
engaged under heavy load preventing premature wear or failure of the clutch plates.
Clutch lever free play gain is created when the EXP friction disk expands and lifts the pressure
plate and pressure plate adjuster off the center clutch nut. By applying light pressure to the clutch
lever with your finger, the throw-out will rest against the pressure plate. When the engine is
revved, the EXP friction disk will expand and lift the pressure plate. With the light finger pressure
on the lever, the throw-out will move outward, following the pressure plate, and the clutch lever
will move inward slightly.
With the engine at idle, apply light inward pressure with your finger on the clutch lever; enough
pressure to take up any slack but not enough to lift the pressure plate. While continuing to apply a
light inward pressure on the clutch lever, rev the engine to at least 5000 RPM.
The clutch lever should move in slightly under light finger pressure as the engine revs. This
movement is called
free play gain
. Free play gain is your indicator that the pressure plate is
being lifted by the EXP friction disk, allowing the force of the clutch springs to be transferred to
the clutch pack.
With the recommended installed gap setting and the engine at normal operating temperature, the
free play gain
when measured at the end of the lever should be approximately 1/8” (3mm).
When the engine is very hot, there will be more free play gain.
IMPORTANT NOTE:
if you ever suspect your clutch is slipping while riding, stop for a moment,
put the bike in neutral and check for free play gain. If you cannot detect free play gain, stop and
reset your installed gap.
If resetting your installed gap is not possible, ride gently to get the bike home by reducing
acceleration and staying in lower gears with higher RPM. Try not to “lug” the engine as this puts a
larger load on the clutch.
