Hi All,
A short while ago I had my OEM brake and clutch lines changed to Hell stainless steel versions.
I think it was just before that where I had a little free play on the clutch lever.
When my guys did the change over to the Hells, I asked them about the free play.
They adjusted it out but advised if it came back again I may require a new clutch master cylinder.
After a fair run with seemingly no issue, I just noticed I have free play back again on the clutch lever.
Is there anything I can do to adjust or were my guys correct with the new clutch master cylinder replacement call?

Well..the manual states.."there is no free play adjustment for the clutch"..so,IDK what they did to 'adjust' it.It'll start (dis)engaging at approximately 1/2 inch pull.If you've taken care of fluid changes and all...the internals SHOULD be fine at the master.Ever see any tiny black dust or pieces of black particles in that reservoir?I found on my 07 at one point in 50K miles,the return hole got a piece of rubber in it.Made the clutch slip.

There is a little free play at the beginning of the pull. That is supposed to be there for the clutch sensor switch. That is the small black plastic thing with the tiny push pin that rides against the lever stock. After that, you should feel the pressure of the master cylinder from the master cylinder pushrod that fits into the seat in the lever.

If you were not feeling the pressure of the master cylinder as soon as that clutch sensor pin was pushed in, That sounds like air in the system. I recently noticed this after bleeding my clutch line. It seemed to go away after more bleeding. The clutch does not require as much fluid pressure function as the break so I would not stress over a little extra freeplay if that goes away after pumping the lever a couple times. If ordinary use of the clutch during riding doesn't make that clutch feel solid, then there's a problem. I think my clutch has felt a bit soft when I first get on the bike for the past couple years. Maybe not every time. Hard to say until I can ride again. I just went out and tried it and the clutch was solid. With OEM lever, the nob on the end travels about 2" (pushing in the sensor nob) before I feel clutch pressure. The last 2 1/2"-3" is all clutch pressure and the lever travels all the way forward on its own.

Is that what you mean by freeplay, a lack of fluid pressure you feel in the lever? ...or is it that you have pressure the whole travel but the clutch does not disengage the engine until the lever is pulled quite far back? From clutch slippage tests I did last summer, I recall the clutch started engaging the engine after releasing the lever only about an inch (less than an inch, I think). The clutch should start to disengage (slip) almost as soon as you feel fluid pressure in the lever. This is what I recall. I can look up the thread for you for more exact info if that is the problem.

Clutch sensor

Clutch master cylinder push rod

* Last updated by: Rook on 2/24/2015 @ 9:23 AM *

What does the bike do that makes you feel it had excessive freeplay in the clutch lever.

I agree with Grn. There is no stock way to adjust clutch freeplay. All you could do to adjust it would be to use a slightly longer pushrod (decrease freeplay--and this would probably make the clutch slip under heavy throttle) or a slightly shorter pushrod (increase free play--bike might creep forward in 1 with lever pulled back to grip).

Bubbles after hose replacement:
1. At the clutch master, find a nipple bleed screw.
2. Place an 8mm box end wrench over the fitting.
3. Place a wadded up paper towel over the nipple and wrench.
4. Crack the nipple open.
5. Pull the lever to the grip.
6. Close the nipple before the lever hits the grip.
7. Release lever.
8. Pull lever to sense the freeplay removed.
9. Release lever.
10. Pull lever to sense freeplay feels more eliminated by the second pull of the lever.

Dry/Sloppy lever pivot elongation when not lubed as per Rook:

1. Hold lever.
2. Push/pull lever as to find elongation or oval wear at the lever.
3. Remove lever and pivot pin bolt to examine elongation vs air bubbles.