FZRSupport: the FZROnline Archive

Hi guys,

Sorry for the long winded post but Im at a loss here and really need some help.

I replaced the clutch while my motor was open, but now the clutch will not release. If I try to put the bike in first, the bike will jump forward and stall as if the clutch handle was not being pulled.

The clutch plates were replaced with aftermarket items as I couldn't get eom ones at the time I ordered. I soaked these for a few days before I installed them. I have also measured them and they are within spec.

The clutch steels are new and eom yamaha parts. They are also within spec and not warped.

The springs were replaced with ebc items. These are shorter than stock. I unfortunately threw the old items away, So I have ordered new eom springs which should arrive today, but I'm not convinced these are the problem.

I have bled the clutch master numerous times and am certain there is no air left in the system.

The pushrod was slightly bend orignally, but I have straightened it. The ball bearing is also definitely installed.

The oil is new mineral based motul. I have also drained the first batch of oil that was run through the motor after reassembly, and replaced it with fresh oil, just in case there was any remnants of kerosene from when the motor was cleaned.

If I remove the clutch cover and operate the lever, I can see the clutch moving. I don't know exactly how much travel is required for the clutch to release, but it looks like its moving far enough.

The clutch basket shows signs of wear, but not enough to cause the plates to bind and get stuck. I can slide them in and out by hand easily.

The clutch springs were not over tightened. In fact the last time I intentionally left the bolts slightly loose so that the plates had some free play between them even when the lever was not being pulled. The result was the same, the clutch still would not release.

Previously I would drain the oil from the sump drain before opening the clutch cover, but as this was getting tedious. So the last time I figured I would drain the oil out the side cover. To my surprise nothing came out and the clutch was completely dry (I must mention at this point that the bike is in the side stand). If the bike is tilted upright, oil does run across to this side of the case. Is this normal or an indication that the oil level is too low?

I also noted that the clutch plates were sticking together.Isnt this something that happens with old worn out clutches not new ones, or could this be due to the lack of oil?

Im hoping there is something minor I have overlooked as I need to get the bike back on the road in the next few days.

Thanks in advance

you need to make sure the clutch disk that holds the plates are torq to spec. also make sure the cover is place on correctly i think i seen a how to on youtube for a fzr600 . after you do all this which i had the same problem check the clutch lever itself ,ake sure that the wire is placed in its bracket both at the clutch lever and in the inside of the clutch cover. mine was fairly loose so my clutch would not grab i wiggled a bit and got it in the correct place adjusted the clutch lever itself and now my clutch runs great. good luck wish i could be of more help

I'm fairly certain the plate was on the correct way, but I will double check and report back.

Thanks

An improperly installed pressure plate will cause a slipping clutch, not a binding / grabbing situation.

A couple of mm movement in the plates is plenty. I dont know much of these bikes but i recon oil shouldnt come out of removed clutch cover with bike on side stand. Look at your oil sight glass height....Its only slightly above your clutch cover....and when on the side stand...
I think the clutch gets most of its oil from the holes in the clutch boss and flings out onto the plates. Oil is not your problem. And of coarse they stick together when operating the clutch idle and watching it, only one plate needs to unstick when clutch isnt turning. Dont worry about that.
Why not try running next to your bike before putting it in gear and see how it performs from there?
Is your side stand up?

Clutches.... Nightmare!

I had a right shit with mine. I swapped plates then steels. Then more steels, more plates, etc etc.

My advice, just buy new new Yam items. Check fluid, seals and clutch operation, tighten slave cylinder to casing properly and you are good to go.

No oil should be lost when changing the clutch on the side stand, this is normal.

Grabbing can be caused by warped plates. Clean the steels from oil and hold them together up to a bright light, you should see no gaps at all. Do the same with the friction plates, press them together, if they warped you will feel springiness. Total stack height could be an issue if your frictions are too thick.

Air in the system could cause plates not to release fully.

Incorrect fitment of the slave could cause your problem, if it is loose for example.

I think I found the problem. The sprocket cover that the clutch slave bolts into is cracked. It was flexing when the clutch was pulled, so I've ordered a used one off ebay. I'm hoping that cures the problem.