Front sprocket cover clutch disengage issue

[shieldr]

Hi, I recently had a snapped clutch cable. On further investigation I found that the pivot joint on the worm mechanism was seized so that had been the likely root cause of the failure. For easyness I ordered a replacement front sprocket cover with a freely moving worm actuator. 

The problem i now have is that when I put the new front sprocket cover assembly on I can’t get the clutch to disengage. The clutch actuator is clearly pushing the clutch rod when I am tightening the font sprocket cover up. I have tried a new 0.5 mm gasket but the problem remains. When I compared the 2 front sprocket covers it did look like the ball on the worm mechanism on the old one that doesn’t disengage the clutch permanently sits a little deeper. I scooted the ball of the replacement worm with wd40 and loosened it a bit but the problem remains. Has anyone else had this problem. I feel like if I fit a 2 mm gasket then that may work but I shouldn’t have to tia, Richard.

[unfazed]

FZS600 Clutch Adjustment
Sometimes after replacing the clutch friction plates or the sprocket cover, the clutch will not work properly.
Usually, it is out of adjustments and needs to be adjusted at the cable end, the Sprocket end or both.
Try adjusting the clutch this way

1. Screw the cable adjuster back in full at the lever end.
2. Remove the rubber bung on the sprocket cover. Loosen the lock nut with a deep good quality ring spanner or a 6-sided socket to loosen the locknut (it will loosen with a crack and frighten the crap out of you).
3. Turn the lock nut anti clockwise a full turn.
4. Turn the centre screw anti clockwise a full turn with a good fitting flat screwdriver.
5. Pull the lever and hold your fingers lightly on the clutch lever as if pulling in the clutch.
6. You will feel the lever moving out.
7. Keep turning the screw until the lever is about 5 to 6mm from the lever housing.
8. Use a ring spanner to tighten the lock nut while holding the adjust in position with the
screwdriver.
9. Grease it well with plain grease
10. Replace the rubber bung.
11. Make any final adjustments at the cable adjuster.
12. If you cannot get less than 10mm at the lever or the adjuster screw tightens replace the cable.

[shieldr]

FZS600 Clutch Adjustment
Sometimes after replacing the clutch friction plates or the sprocket cover, the clutch will not work properly.
Usually, it is out of adjustments and needs to be adjusted at the cable end, the Sprocket end or both.
Try adjusting the clutch this way

1. Screw the cable adjuster back in full at the lever end.
2. Remove the rubber bung on the sprocket cover. Loosen the lock nut with a deep good quality ring spanner or a 6-sided socket to loosen the locknut (it will loosen with a crack and frighten the crap out of you).
3. Turn the lock nut anti clockwise a full turn.
4. Turn the centre screw anti clockwise a full turn with a good fitting flat screwdriver.
5. Pull the lever and hold your fingers lightly on the clutch lever as if pulling in the clutch.
6. You will feel the lever moving out.
7. Keep turning the screw until the lever is about 5 to 6mm from the lever housing.
8. Use a ring spanner to tighten the lock nut while holding the adjust in position with the
screwdriver.
9. Grease it well with plain grease
10. Replace the rubber bung.
11. Make any final adjustments at the cable adjuster.
12. If you cannot get less than 10mm at the lever or the adjuster screw tightens replace the cable.

Thanks for this advice. I will definitely take a look at this. One thing I would say is that when I put the original sprocket cover on the clutch operates fine. Any thoughts on this? Thanks ?

[shieldr]

FZS600 Clutch Adjustment
Sometimes after replacing the clutch friction plates or the sprocket cover, the clutch will not work properly.
Usually, it is out of adjustments and needs to be adjusted at the cable end, the Sprocket end or both.
Try adjusting the clutch this way

1. Screw the cable adjuster back in full at the lever end.
2. Remove the rubber bung on the sprocket cover. Loosen the lock nut with a deep good quality ring spanner or a 6-sided socket to loosen the locknut (it will loosen with a crack and frighten the crap out of you).
3. Turn the lock nut anti clockwise a full turn.
4. Turn the centre screw anti clockwise a full turn with a good fitting flat screwdriver.
5. Pull the lever and hold your fingers lightly on the clutch lever as if pulling in the clutch.
6. You will feel the lever moving out.
7. Keep turning the screw until the lever is about 5 to 6mm from the lever housing.
8. Use a ring spanner to tighten the lock nut while holding the adjust in position with the
screwdriver.
9. Grease it well with plain grease
10. Replace the rubber bung.
11. Make any final adjustments at the cable adjuster.
12. If you cannot get less than 10mm at the lever or the adjuster screw tightens replace the cable.

Thanks for this advice. I will definitely take a look at this. One thing I would say is that when I put the original sprocket cover on the clutch operates fine. Any thoughts on this? Thanks ?

Process worked a dream first time thanks. Bike is now back on the road ?