Clutch change question

[adeejaysdelight]

F.A.O Moderator - please leave this here for a couple of days so I can get feedback from ex FZS 600 owners.




Hi Guys,


I changed my clutch plates and springs to EBC heavy duty stuff. I also changed the chain and sprockets and broke the gear selector rod whilst doing so, therefore I had to change that too. When I built the clutch back up, I did it one piece at a time, so I know that side is ok.


So, today I assembled it all and when I pull the clutch lever - nothing happens. It is flaccid. I was wondering if I need to change the clutch cable to? It is probably the original one, so about 32K old. Will this solve my problem, or have I made an error somewhere else?


Any help appreciated

[CRH]

did you put bk the clutch pushrod?..and reset the clutch at the casing end?

[adeejaysdelight]

Reset the clutch?

[Punkstig]

When you had the sprocket cover off you may have dislodged the little ball that sits in the sprocket cover, take the cover back off and have a look at the piece that attaches to the clutch cable and twists when the cable is pulled in.

[adeejaysdelight]

That could be it Stig. I did have a look at the section where the cable is attached. There is no "ball". I have swept out my garage today after I finished, so if the ball was on the deck, it is now in my wheelie bin  . What size is it and how does it attach?

[Punkstig]

If there's just a hole there then it could possibly have dislodged and be inside the mechanism!


There's another recent thread that says that mechanism it's a bitch to remove as the bolts are cheap shite!

[Punkstig]

Have a look here
http://foc-u.co.uk/index.php/topic,10124.25.html


Unfazed has provided pics of the mechanism I'm talking about on page 2 which shows the 'ball' still in!

[His Dudeness]

Are you sure the plates are seated in the basket properly? Is the cable in the sprocket cover and lever properly? Is the sprocket cover on properly? Did you take the pushrod out? The steel ball is at the end of that.

[Deefer666]

The Ball goes between the push rod and the "mushroom" shaped push mechanism on the basket side, Also did you line up the dots on the basket and outer? , if not you will have nothing

[Stooby2]

A J Sutton to the rescue. Love this site for the diagrams if nothing else - but they give excellent service too...


http://www.yamahamotorcyclespares.co.uk/genuineparts/9796/16/yamaha%20fzs600%20fazer/clutch?uID=0


You can see the ball bearing - No.19 - and if you need a new one, order it from the site

[adeejaysdelight]

I have stripped the clutch cover back off the bike. The problem seems to be the clutch pressure plate (number 8 in the diagram). 7 of the 8 spring seats have broken at the collar. I don't know if this is because I have used EBC heay duty springs or not. I torqued them up to the right setting (8nm), but they have crumbled anyway. Looks like I need to get a replacement. The joys of motorcycle ownership.

[alan sherman]

I bet you didn't get the clutch basket back on the correct way.  When you torque the nuts up they break the collars.  The clutch doesn't work as the plates don't come into contact with each other.

I may have done this myself.  Stupid but hey, it happens.  Make sure the clutch basket is aligned correctly before reassembling.

[Dead Eye]

I'm guilty of doing this as well

Ended up buying a clutch basket for about £40-50 if I remember correctly

[Stooby2]

Yep welcome to the "been there done that" club. You have to make sure the plate seats properly, keep turning it round until it does.

[adeejaysdelight]

Ok Guys, so this is a rooky error? Its my first clutch change, although I am still pissed off with myself. So what exactly am I looking for? All of the plates are back in and feel secure. Is there some kind of alignment or something? Do they lock in place... I don't want to destroy another pressure plate 

[Dead Eye]

You need to make sure that the inner splines of the pressure plate align properly and seat perfectly