clutch is heavy FZS600 1999

[flakey]

hi guys, I'm really struggling to use my clutch after riding for 30mins or so, it seems my hand cant pull the lever in any more and hurts like hell-(guessing arthritus) I have taken the clutch cable off and lubed with oil-not seeing or feeling anything wrong with the cable once its off the bike as all moving freely and smooth, I have ordered another genuine clutch cable and waiting for it to arrive, is there anything else I could check or do to free up the clutch and make it Lighter? all sudgestions will be much appreciated.


thanks guys

[Jules-C]

Clean and grease the clutch mechanism in the sprocket cover.

Also the clutch lever pivot

[unfazed]

Quite possible someone fitted EBC springs to the clutch before you got it?. If so the only solution is to fit standard springs.

There is a file in the download section on how to grease the mechanism in the sprocket cover.

[flakey]

thats great, thanks guys, that download looks brilliant, right up my street with pictures, thanks

[Bretty]

Is it worth moving the clutch lever slightly inboard / right, so your fingers are more on the end of the lever. It should give you a bit more leverage although a little more travel.

Just thinking out loud.

[unfazed]

thats great, thanks guys, that download looks brilliant, right up my street with pictures, thanks

Do not attempt to remove the mechanism without a left hand drill bit and variable speed drill, the bolts will either shear or you will destroy the heads. They are very very soft bolts loctited in place.
If you feel you have to remove it then a left hand drill bit with a variable speed drill will created enough heat to soften the loctite and spin out the screws also.

[flakey]

New clutch cable finally arrived today, ive fitted it an regreased the bearings in the left hand clutch housing, it seems the clutch housing is my issue as the spring is really strong, niw do yamaha do a softer spring for the left hand cable housing? Would it work if i stretched the spring in there thus requiring less force to pull the lever in with?
Thanks

[unfazed]

Did you check the the cable pull with the sprocket cover off.
The spring in the cover is very light and only to pull the lever back to its home position.
Does the spring look like the one in the picture below, if it is and the pull on the lever is fine with the sprocket cover off, then your problem as I stated previously is heavy duty clutch springs and need to be replaced with standard ones

[flakey]

Mine looks the same as that picture, moves very smoothly but is stiff even without the cable attatched and off the bike

[Jules-C]

Sounds like the mechanism in the sprocket cover is seized if it heavy to operate off the bike.  It needs cleaned out and regreased.

[Dave48]

Sounds like the mechanism in the sprocket cover is seized if it heavy to operate off the bike.  It needs cleaned out and regreased.
[/
+1 Wash out all the old crap with paraffin.  Dry out and regrease mechanism. If clutch still stiff after doing all these suggested things to cable,pivot etc then the problem must lie in the clutch itself-springs?quote]

[paulchucky]

strip the mechanism and throurly clean and grease and clean the housing worm mechanism  the lever should be easy to pull in 

[unfazed]

Mine looks the same as that picture, moves very smoothly but is stiff even without the cable attatched and off the bike

Ok now we know what the problem is. What you need is spray on grease, something like spray on lithium grease and a can or WD40 Available in Halfords or local bike shop or auto factors. At least Halfords are open on Sunday

Before you strip any thing, remove the rubber bung, loosen the lock nut and remove it then turn the screw in full..
Remove the sprocket cover and remove the clutch cable.
Place the cover inside down on a flat surface with a few rags under it.

Fill the hole where you removed the locknut and screw with WD40 leave it for 15 minutes, There is a seal on lever inside to keep the grease in, but the WD will probably leak out slowly. Keep the hole filled to allow the WD$)  to soak through the corrosion.
Try operating the lever and it should get progressively easier. Repeat the process until it is free moving. When movement is free remove the internal screw and let the WD40 drain as much as possible.

Now follow the instructions posted her http://foc-u.co.uk/index.php?action=downloads;sa=view;down=60