Date: 29-03-24  Time: 04:36 am

Author Topic: FZS 1000 Gen 1 clutch cable replacement  (Read 1097 times)

sandi

  • Cager in Training
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    • Main bike:
      FZS 1000 Gen1
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FZS 1000 Gen 1 clutch cable replacement
« on: 24 August 2017, 03:54:15 pm »
Hi,
As I have not found some sort of a tutorial for the clutch cable replacement on Gen 1, I'm writing this as a possibility to help someone else who's doing it by themselves.

Note 1: My bike is converted to 'naked', thus does not have the original fairing. That's why I'm not including the part with the disassembly of the fairing.

Note 2: I'm not sure whether that's the most correct way of doing it, but it was fairly simple and quick job.
(Off course I didn't take pictures while doing it, so I am uploading cropped old pictures :) )

Step 1: Release the tension on the cable by unwinding the top adjuster on the clutch lever. (If the cable is broken I don't think it's necessary)

Step 2: Release the bottom end of the cable by gently prying the metal that holds it in place, then push the clutch arm as if the cable is pulled, then move the cable out of the cradle it sits in normally.
The cable should be now loose at the bottom end.

Step 3: Remove the clutch lever from it's support by unscrewing a 10 mm nut at the bottom of the bolt, that is used as a pivot. (In my case I had to loosen the 8 mm bolt and rotate the whole clutch lever assembly in order to reach the 10 mm nut.) After removing the lever, remove the cable from it.

Step 4: Loosen the 12 mm nut at the bottom end of the cable and pull it out of the metal bracket that holds it. You have to use a second 12 mm spanner as there are two 12 mm nuts.

Step 5: On the left side of the bike, near the bottom end of the leftmost carburetor, near the adjuster lies the clutch cable on a bracket. Be careful as the rubber sleeve on the bracket was a bit torn and could fall easily and the clutch cable could rub against the metal. Pull the cable all the way from the left side.

Step 6: There is a plastic clip, holding the cable, under the frame, above the top part of the leftmost carburetor. Unclip it using a small flat screwdriver in order to release the cable.
After that you can easily pull out the rest of the cable from the middle section, i.e. the top part of the cable should be pulled out and downwards, NOT the rest of the cable pulled upwards. (Probably the other way round could work too, but I doubt it would be easier)

The installation of the new one I did by basically doing it all in reverse. Note the route of the cable before you pull it out, especially at the top part, after the plastic clip, where the cable goes above the carburetor and to the clutch lever. If you reroute it incorrectly you risk the cable rubbing in some metal parts or electrical wires. The cable assembly with the sleeves and metal bends and corners is specifically made to operate this way and if you bend it out of shape or reroute it incorrectly, the clutch pull could be harder and the cable inside may wear out prematurely.
« Last Edit: 24 August 2017, 04:57:08 pm by sandi »