Pg. 18
Doc ID: 191-7911A
Doc Rev: 080420
installed gap. The amount of Free Play Gain you feel in the lever
corresponds to the amount the pressure plate has been lifted by the
EXP disk expansion.
Checking Free Play Gain allows you to externally monitor the
installed gap so you can know when to make an adjustment if the
installed gap is too large or too small.
The correct installed gap is verified by observing and feeling the
increased free play movement in the clutch lever. This extra
movement is called “Free Play Gain.”
If there is too much Free Play Gain, the installed gap is too small.
The bike may drag and stall because it has difficulty disengaging
the clutch. It may also be difficult to shift. Too much Free Play Gain
will not hurt the clutch, but it will negatively affect clutch
performance.
With too little or no Free Play Gain, the installed gap is too large.
This means when the EXP is fully expanded it does not lift the
pressure plate. The clutch may slip and make the bike seem like it
is losing power. The bike may not move forward even though the
engine RPM increases as if the clutch lever is slightly pulled. Too
little Free Play Gain will cause the clutch system to burn up.
Optimal Free Play Gain yields 1/8” (3 mm) of clutch lever
movement, measured at the ball end of the lever. This
measurement at the lever correlates to achieving the ideal installed
gap.
