For some reason my file on the clutch acuuator adjustment did not upload last time. Use this method as you can feel the adjustment working.
The bottom line, back off the sprocket clutch adjuster, and adjust it,as in the download, take off the clutch cover and check the pressure plate lifts when you pull in the clutch lever. If not remove the pressure plate and press and hold the clutch push rod in with your finger, pull in the lever, does it push your finger. (I presume your new clutch pressure plate had the release bearing in it) if it does push you finger out a bit and there is a bearing in the pressure plate. Then the issue is most likely that the pressure plate is fitted incorrectly or the friction plates are incorrect. The pressure plate has a wrong and right way to fit it. The wrong way appears ok, but tightening the bolts can break the pressure plate like most likely what happened to your original pressure plate. If unsure fit the pressure plate remove it rotate it and fit it again. The wrong way will be obvious as the plate will not slot in completly even though the bolt holes will have lined up.
This have not been approved yet in the downloads
FZS600 Clutch Adjustment
Sometimes after replacing the clutch friction plates 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, but first ensure the Clutch lever pivot hole is not worn and cable is not frayed causing the elongation of the cable They can fray at the handle bar or inside the sprocket cover. Take off the sprocket cover off and check it If all ok with the cable and lever then follow this method:
1. Screw in the cable adjuster 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 and/or the adjuster screw tightens fully replace the cable.
In your case number 12 will aply when yo have checked the clutch itself
The bottom line, back off the sprocket clutch adjuster, and adjust it,as in the download, take off the clutch cover and check the pressure plate lifts when you pull in the clutch lever. If not remove the pressure plate and press and hold the clutch push rod in with your finger, pull in the lever, does it push your finger. (I presume your new clutch pressure plate had the release bearing in it) if it does push you finger out a bit and there is a bearing in the pressure plate. Then the issue is most likely that the pressure plate is fitted incorrectly or the friction plates are incorrect. The pressure plate has a wrong and right way to fit it. The wrong way appears ok, but tightening the bolts can break the pressure plate like most likely what happened to your original pressure plate. If unsure fit the pressure plate remove it rotate it and fit it again. The wrong way will be obvious as the plate will not slot in completly even though the bolt holes will have lined up.
This have not been approved yet in the downloads
FZS600 Clutch Adjustment
Sometimes after replacing the clutch friction plates 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, but first ensure the Clutch lever pivot hole is not worn and cable is not frayed causing the elongation of the cable They can fray at the handle bar or inside the sprocket cover. Take off the sprocket cover off and check it If all ok with the cable and lever then follow this method:
1. Screw in the cable adjuster 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 and/or the adjuster screw tightens fully replace the cable.
In your case number 12 will aply when yo have checked the clutch itself