Clutch and Throttle freeplay adjustments for better response

FREEPLAY ADJUSTMENTS

Freeplay ensures that the clutch is fully disengaged when we leave the clutch lever. Which means the power is transferred to the wheel without any slippage. A minor constant slippage not only damages the clutch plates but also increase the engine working temperature. As most of the bikes now a days using wet clutches, even little slippage can cause a frequent engine oil replacement and makes the clutch lifespan short.
In order to keep things safe, we use freeplay.

Clutch Freeplay Adjustment

Now freeplay can be good if we consider all the above points, but more freeplay also causes lag between lever operation and disengagement. This lag would then be enough to ruin every quick shifts.
Hence we tune it to some extent where it doesn't affect our shifting but keeps the engine and clutch safe.

Freeplay adjustment requires tuning from 2 points:

Fig1:Point where the clutch cable connects to the clutch lever down near to engine.
Fig2:Point where clutch cable connects to the handle lever (fine tuning)

Step 1 will be performed on the main clutch lever

In case of Yamaha R15, the clutch is partially accessible on the left hand side without any necessity to open the side fairings. But for a better demonstration I will show how to open side fairings.

All you need is a screwdriver and a 4mm hex key

First you need to locate and unscrew all the hex bolts

Also, you need to open 3 screws also which is located between the 2 of the side fairings.

The  third screw which is not visible in the image can be found in the line where second screw is situated.

After this carefully pull the side fairing so that it comes out of the lug provided.









There you go. The fairing is out now!

Now for clutch tuning, following the below given easy steps:

The Main adjustment:

• Crack up the lock nut and loose the adjusting nut till clutch lever reaches the end point. This ensures that the clutch is completely disengaged along with the freeplay.

• Now adjust back the screw to introduce the freeplay you need. The freeplay should be as minimum as possible. 

• Once the setup is down, tighten the lock nut to hold the setup made.

• Clean up the cable and lubricate with either grease or oil. You can use grease to lube the inner part of the cable. For the exposed part grease should not be used. You can apply some used engine oil here.

Fine Tuning

Fine tuning is the most important part of the adjustment as this is the actual calibration of the operating lever. 

More freeplay may affect shiftings, less may affect the operations and control. 

• First remove the cover provided to gain access. 

• Loose the lock nut in the direct shown and rotate the main nut as well (opposite to the direction shown) to tight the lever at its full extent

• Now rotate the main nut(same as shown) to set the lever freeplay. This is the most important adjustment for freeplay. The freeplay should be as minimum as possible so that the rider will not feel much drag in the lever operation.

• Note that freeplay between 2 to 3mm should be fair enough any less or more is not recommended.

• Clean and lube the cable end and cover it back

The setup may not be the best at first. In order to find the perfect tune, test drive and perform several trial and error iterations for setting up everything just right!

Throttle freeplay adjustment

As clutch, the throttle freeplay also plays a major role in controls. More freeplay might feels a=like lagging throttle and less might affect the engine idling.

For R15, Yamaha was giving the idling adjustments handy so that the rider can set it on its own.
But 2014 onwards, there is no idling adjustment options. The screw were removed and the idling is now controlled by ECU completely.

This decision made by Yamaha is actually good as disturbing the idling not only affects performance but engine life as well. Supplying any less is a waste and supply more can affect the fuel economy.

For R15, the main throttle access is a bit difficult to get. The access is situated just beneath the fuel tank. Hence for main adjustment, fuel tank has to be out.

To open the fuel tank, we need 5mm hex key and a screw driver.

Fig1: Open via screwdriver
Fig2: Open via 5mm hex
Fig3: Open via 5mm hex from both sides
Fig4: Situated near the handle bar, open via 5mm hex





Now we need not to disconnect the entire tank. You can either place it there itself or ask a second person to hold it till you finish the adjustments.

Now the setup is similar to that of clutch. Loose the lock nut and calibrate the adjusting nut.


Make the lock nut tight again after finishing.

• Now coming to the handle access, the initial idling reading from the tachometer. 

• Default is 1500 rpm and 1000 rpm if the engine is already warm

• Remove the cover to see the adjusting nuts

• Loose the lock nut and adjust the throttle twist with the adjusting nut.

• The freeplay will be up to a certain degree of the twist to which the throttle does not respond. 
• The recommended throttle play should not be more 5 degrees.

Ensure the engine idling is not affected by the new adjustment. If so, repeat to find the fine tuning.



Note:

1. As we are using the cables in this bike, the adjustment should be checked periodically.
Sometimes we may experience the expansion with different seasons and operations (As the metal expands with increase in temperature). Hence it is recommended to have little adjustments in regular intervals including lubricating and cleaning. If necessary, changing the clutch cable is also fine.

2. Engine oil express much when it comes to clutches health. If the oil is degrading before time or see a radiator hitting before expected time, there are chances that the clutch or its operation is not proper.

3. Check the free movements of the cables specially at all pinch points. Friction might cause damage to cables.