Carl_1973 Posted August 27, 2015 Share Posted August 27, 2015 Hi,I have just changed the Clutch Cable on my FZ6 SA (2007). The job itself was relatively straight forward. Once I had set the cable tension correctly I started the bike up for a test ride. 1. The Clutch lever is excessively loose, IE it takes almost no effort to depress the lever to engage the clutch2. The Clutch release mechanism on the lower right hand side of the engine seems to have full movement in and out.When I put the bike in gear it jumps and stalls.When I start the bike in gear with the clutch depressed it jumps also as the bike is in gear but seemingly the clutch is not engaged.I hasten to add that by all accounts the clutch mechanism is seemingly engaged fully but not doing its job correctly.I'm am relatively new to Bike mechanics but did use my faithful Haynes Manual to change the Clutch Cable. I would appreciate any suggestions that members have.Thanks in advanceCarl Quote Link to comment Share on other sites More sharing options...
Stu Posted August 27, 2015 Share Posted August 27, 2015 Hi and welcome to the forum If your clutch worked before the cable change then its out of adjustment somewhere Some systems are a twat to get right and if not right then you get the symptoms you describe or it slips! Sounds like the slack on the push rod needs taking up Can you get some pics of the mechanism for us Quote Link to comment Share on other sites More sharing options...
Grumpy Old Git Posted August 27, 2015 Share Posted August 27, 2015 You need to adjust / set up both ends of the cable - It sounds like the clutch push-rod end is incorrectly set. Quote Link to comment Share on other sites More sharing options...
eastanglianbiker Posted August 27, 2015 Share Posted August 27, 2015 as stu said welcome to the forum setting up the cable start by winding the adjuster on the handlebars right into the lever then loosen the nuts down on the clutch actuator arm and take up the free play there untill u feel it start to get resistance then back it off 1/4 of a turn lock off the nuts check play at handlebar and fine adjust there as needed that is the basics of setting it up Quote Link to comment Share on other sites More sharing options...
Carl_1973 Posted August 27, 2015 Author Share Posted August 27, 2015 Hi and welcome to the forum If your clutch worked before the cable change then its out of adjustment somewhere Some systems are a twat to get right and if not right then you get the symptoms you describe or it slips! Sounds like the slack on the push rod needs taking up Can you get some pics of the mechanism for us I haven't taken off the clutch casing or anything. What pics would enable you to ascertain if it was "slack on the push rod". Would simple tightening the clutch cable enable this? Quote Link to comment Share on other sites More sharing options...
Carl_1973 Posted August 27, 2015 Author Share Posted August 27, 2015 as stu said welcome to the forum setting up the cable start by winding the adjuster on the handlebars right into the lever then loosen the nuts down on the clutch actuator arm and take up the free play there untill u feel it start to get resistance then back it off 1/4 of a turn lock off the nuts check play at handlebar and fine adjust there as needed that is the basics of setting it up My cable has a mid way adjuster which is under the air box and the one at the lever. For all intense and purposes the adjustment seems fine and fully pulls / releases the clutch actuator to its intended limit. To be honest I'm baffled, I even got my mate to manually use the clutch actuator and it still had the same problem. Quote Link to comment Share on other sites More sharing options...
Stu Posted August 27, 2015 Share Posted August 27, 2015 I haven't taken off the clutch casing or anything. What pics would enable you to ascertain if it was "slack on the push rod". Would simple tightening the clutch cable enable this? its the part that the clutch cable attaches to is what I'm more interested in no adjusting the cable wont help if the mechanism need to be set in a specific way some have a central adjuster which touches the push rod and if its not set right then it wont release the clutch properly or it can cause slippage ps whats your location ? Quote Link to comment Share on other sites More sharing options...
Carl_1973 Posted August 27, 2015 Author Share Posted August 27, 2015 I haven't taken off the clutch casing or anything. What pics would enable you to ascertain if it was "slack on the push rod". Would simple tightening the clutch cable enable this? its the part that the clutch cable attaches to is what I'm more interested in no adjusting the cable wont help if the mechanism need to be set in a specific way some have a central adjuster which touches the push rod and if its not set right then it wont release the clutch properly or it can cause slippage ps whats your location ? I'm located just outside of Nottingham....How do I put a picture up? does it have to be hosted on a website and linked? Quote Link to comment Share on other sites More sharing options...
Stu Posted August 27, 2015 Share Posted August 27, 2015 you can use the service provided here just scroll down once you have hit reply and under the part where you write there is a section to add a picture ensure its not too large otherwise it wont post Quote Link to comment Share on other sites More sharing options...
Carl_1973 Posted August 27, 2015 Author Share Posted August 27, 2015 Photo one... Second showing fully pulled and alignment correct... The actuator rod going into the casing has a little bit of play, about 3mm...Had to resize all the pics.... Quote Link to comment Share on other sites More sharing options...
Stu Posted August 27, 2015 Share Posted August 27, 2015 is that cable slack in the last pic?thanks for the pics its clarifies that you dont have a need to adjust the bottom end Quote Link to comment Share on other sites More sharing options...
Carl_1973 Posted August 27, 2015 Author Share Posted August 27, 2015 Yes, but only because I am manually pushing it to show that that alignment is correct with the arrow and dot...The lever is not under tension. Quote Link to comment Share on other sites More sharing options...
Stu Posted August 27, 2015 Share Posted August 27, 2015 its unusual to be able to move that actuator with your hand! its pulling on 4 maybe 5 springs which makes it very hard work! I'm wondering it the actuator has come off the push rod inside! its a bit hard to know what is exactly going on while sat behind a pc! shame your not closer! Quote Link to comment Share on other sites More sharing options...
Carl_1973 Posted August 27, 2015 Author Share Posted August 27, 2015 its unusual to be able to move that actuator with your hand! its pulling on 4 maybe 5 springs which makes it very hard work! I'm wondering it the actuator has come off the push rod inside! its a bit hard to know what is exactly going on while sat behind a pc! shame your not closer! I concur, its a difficult question to answer, I do like your thought though as the lever pull is very slack.I thought it quite strange, but find it even stranger that simply removing the cable would cause it to come lose in the housing, it looks like I'll have to order a new gasket and then take the cover off to have a shufty. I would also like to thank you taking the time to have a blast at solving my problem, why is it the little jobs end up being epic Quote Link to comment Share on other sites More sharing options...
Stu Posted August 27, 2015 Share Posted August 27, 2015 you can normally get away without replacing the gasket just ensure the bike is on its side stand and you have a catch tray underneath just in case any oil drops out I do suspect that the mechanism has somehow come off if its really loose I cant be too sure without looking at it myself! Quote Link to comment Share on other sites More sharing options...
Stu Posted August 27, 2015 Share Posted August 27, 2015 does this help at all? https://www.youtube.com/watch?v=U_J3fE66kQs Quote Link to comment Share on other sites More sharing options...
Carl_1973 Posted August 27, 2015 Author Share Posted August 27, 2015 I'll pop it tomorrow then.it'll be something daft as it always is. Quote Link to comment Share on other sites More sharing options...
Carl_1973 Posted August 27, 2015 Author Share Posted August 27, 2015 Its certainly something I will try first that's for sure....Good old Youtube... Quote Link to comment Share on other sites More sharing options...
Carl_1973 Posted August 28, 2015 Author Share Posted August 28, 2015 Stu,Bike fixed this morning. It was the Clutch Slave Lever. After doing the fix from the YouTube video it became apparent the new Clutch Cable was too long (who'd have thought it). I put the old one back on and it works like a dream on minimal adjustment. I would imagine the old cable seemed at max adjustment due to the Slave Lever being mis-aligned but now its fixed the old cable has ample adjustment left. Once again, thank you for your invaluable advice, its only easy if you know the answer.Carl Quote Link to comment Share on other sites More sharing options...
Stu Posted August 28, 2015 Share Posted August 28, 2015 Excellent Makes sense really Glad you have it sorted Quote Link to comment Share on other sites More sharing options...
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