So I rebuilt my clutch, and adjusted all three points with the help of this great write up:
http://gstwins.com/gsboard/index.php?topic=20468.0
But the friction zone seems to be a lot larger, too much for my liking. From a stop, it will engage when the lever is pulled in about 3/4 of the way. However, when I blip/downshift the clutch won't engage until the lever is almost all the way out. I'm not sure if this is normal or not, but it didn't seem to happen before I replaced the clutch. So my confusion is:
Loosening the pushrod adjustment screw more than the recommended 1/4 of a turn from resistant will give it more freeplay, and widen the friction zone? I'm not sure exactly how the clutch pushrod affects the clutch lever action. I've played with it a few times but not a lot seems to be changing - I'm looking for a much narrower friction zone, almost an on/off kind of thing.
When adjusting the clutch pushrod screw, do you guys usually screw in until you feel slight resistance or until it locks? there seems to be about a half turn difference between the two.
Also, for about a week now I've had to readjust my clutch cable (just from the lever) almost everyday, it seems to be moving around a bit. Do new clutches require a little break in time? Either that or I'm worried that the clutch cable is stretching/worn.
My Suzuki Service Manual sez..1/4-1/2 turns out from resistance
I use 1/8th of a turn out when I feel the screw touch the clutch rod.I run my mix of SV650 racing clutch parts so wear should be slow.Here's my clutch thread for the curious people looking on. http://gstwins.com/gsboard/index.php?topic=56043.0 I also set my clutch lever free play at about 2mm.I have a new clutch cable so it will stretch over time.
None of the clutch adjustments mentioned will narrow the friction zone. Actually, a wide friction zone is a sign of a healthy clutch. You can move the the engagement point closer to the bar by taking slack out of the cable but the pushrod adjustment is only there to provide adequate clearance when the clutch lever is let go. Without that clearance the clutch will be more likely to slip and slack in the cable won't help :technical: Too much clearance has to be adjusted out by eliminating freeplay at the lever :nono: