FZ1-N Clutch Cable Adjustment and Free Play

[Suntan Sid]

I bought my current bike, (2006,FZ1-N), 2 years ago.
Since buying it I've done the usual stuff, oil and water changes, brake pads, replacing bulbs, new tyres etc. I've got a project bike to tinker with, so the FZ is just a ride it and forget it about bike.

For no particular reason, after a blast earlier in the week, I noticed the clutch lever wasn't returning fully, no problem that's just the free play in the cable, I thought. (I've not noticed anything different recently, so I suspect it's been like this since I got it).

I undid the cable at both ends and lubed up, reattached everything but the lever was still, somewhat, stiff and not springing back. It turns out "Heman", or some other character from Masters of the Universe had tightened the nylock nut on the clamp, backing it off a little bit seemed to get rid of the stiffness and allowed the lever to spring back into place.
The problem, however, is that I cannot get any free play, whatsoever, at the lever. The tiniest movement of the lever moves the clutch actuating arm. The marks on the arm and the casing do line up and going by feel at the lever, I believe that the first bit of movement of the arm is not moving the clutch?

The manual says there should be 10-15mm of free play at the lever.
The manual also says that if you cannot achieve the required free play using the adjuster at the lever, to use the adjuster under the tank.

So I popped the tank up and spent 20 minutes trying to find the adjuster, turns out there are two, both of which are totally and utterly inaccesible, despite what the manual says. You cannot get a spanner anywhere near either of them, a midget gynecologist would have problems, FFS.

So my question is this, given that my bike runs fine, is very low mileage for the year and the clutch does not slip or drag, should I be bothered about not having or not being able to get any free play in the clutch cable?
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"Everybody needs money, that's why they call it money!"

[CaNsA]

No free play.... lining yourself up for many clutch slippings.

[Ridersofthest...]

Follow the manual on this and get the freeplay.

[Suntan Sid]

[Nobby the Bastard]

You undid the cable at each end? That'll require you to remove a casing (assuming it's a typical Yam). Has a ball bearing\shim, fallen out where the mech meets the pushrod?
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

[delsol]

I find this very interesting, guessing Suntan Sid refers to user manual as opposed to workshop or Haynes manual.

If the manual says that adjustment can be made under the tank then that must be so.

Anybody have a pic(s) from a workshop manual showing access/adjustment procedure on tank underside.

I just can't see how op cannot access adjusters if THE BOOK tells you it's an adjustment point(s).

Can't help op, but share your frustration, I wouldn't be able to leave alone until it was sussed out.[/i]

[Suntan Sid]