Hey Guys, I tried searching for any articles related to my issue, I've ordered a new clutch cable but trying to find some advice on replacing it. not much of a mechanic. If someone knows how or could point me in the right direction for instructions I would greatly appreciate it.
Thanks!
Clutch Cable snapped
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Clutch Cable snapped
1991 FZR600
Re: Clutch Cable snapped
Okay.
Disconnect the old one at the handlebar/lever. This will mean turning the adjuster by the lever IN all the way..lining up the slots in the adjuster barrell, jam nut, and clutch lever perch. Then you slip the cable sheath out of the adjuster and perch. There is a cylindrical cable end which lock in the lever. The lever is slotted to allow the cable end to come out when turned 90° to the lever. Do NOT pull the cable down through the bike's frame/chassis at this time.
Remove the allen screws holding the front sprocket cover on (five screws I believe-_note the long one that runs in the middle). You will also have to remove the shift linkage-use a sharpie to mark where on the splines meet the slot of the linkage-remove the 10mm (head) bolt completely or the linkage won't come off. Inside the sprocket cover is a retention clip for the cable. Remove this and don't lose it. The lower cable end is retained in a similar fashion to the upper..you'll figure it out when you see it. Good idea to have some brak-kleen and rags on hand to clean the nasty gunk from under the sprocket cover-it WILL be nasty.
Now, tape the lower end of the new cable's sheath to the upper end of the old cable sheath and use the old cable to pull the new one downwards through the frame. It helps to do a nice tape job (may I suggest duct tape for this) with a smooth transtion from one cable to the other. This will ensure that cable is routed exactly as the old one was. Use the retention clip you didn't lose or if the new cable has a new one on it-use it.
Re-install the sprocket cover, loosen the lower clutch adjuster all the way and connect the upper end.
Clutch adjustment procedure should be followed from this point.
Disconnect the old one at the handlebar/lever. This will mean turning the adjuster by the lever IN all the way..lining up the slots in the adjuster barrell, jam nut, and clutch lever perch. Then you slip the cable sheath out of the adjuster and perch. There is a cylindrical cable end which lock in the lever. The lever is slotted to allow the cable end to come out when turned 90° to the lever. Do NOT pull the cable down through the bike's frame/chassis at this time.
Remove the allen screws holding the front sprocket cover on (five screws I believe-_note the long one that runs in the middle). You will also have to remove the shift linkage-use a sharpie to mark where on the splines meet the slot of the linkage-remove the 10mm (head) bolt completely or the linkage won't come off. Inside the sprocket cover is a retention clip for the cable. Remove this and don't lose it. The lower cable end is retained in a similar fashion to the upper..you'll figure it out when you see it. Good idea to have some brak-kleen and rags on hand to clean the nasty gunk from under the sprocket cover-it WILL be nasty.
Now, tape the lower end of the new cable's sheath to the upper end of the old cable sheath and use the old cable to pull the new one downwards through the frame. It helps to do a nice tape job (may I suggest duct tape for this) with a smooth transtion from one cable to the other. This will ensure that cable is routed exactly as the old one was. Use the retention clip you didn't lose or if the new cable has a new one on it-use it.
Re-install the sprocket cover, loosen the lower clutch adjuster all the way and connect the upper end.
Clutch adjustment procedure should be followed from this point.
http://www.michiganmobileservice.com/
“A common mistake that people make when trying to design something completely foolproof is to underestimate the ingenuity of complete fools.”-Douglas Adams
http://www.youtube.com/user/reelrazor
“A common mistake that people make when trying to design something completely foolproof is to underestimate the ingenuity of complete fools.”-Douglas Adams
http://www.youtube.com/user/reelrazor
Re: Clutch Cable snapped
To replace the cable you'll have to remove the left side fairing and tank cover to get clear access.
Loosen the adjuster at the clutch lever so that it is completely loose
Remove the front sprocket cover and then detach the end of the cable from the actuator on the inside of that cover. Detach the cable from the clutch lever.
If you get some strong string you can tie it to the end of the old cable to the end of the new cable and as you pull the old cable out the new cable will follow with a bit of help along the way.
Attach the new cable to the clutch lever first then attach it to the actuator inside the sprocket cover. Put the cover back on and follow the steps in this thread to adjust the clutch properly.
http://www.fzronline.com/forum/viewtopic.php?f=8&t=7747
Hope that helps.
Loosen the adjuster at the clutch lever so that it is completely loose
Remove the front sprocket cover and then detach the end of the cable from the actuator on the inside of that cover. Detach the cable from the clutch lever.
If you get some strong string you can tie it to the end of the old cable to the end of the new cable and as you pull the old cable out the new cable will follow with a bit of help along the way.
Attach the new cable to the clutch lever first then attach it to the actuator inside the sprocket cover. Put the cover back on and follow the steps in this thread to adjust the clutch properly.
http://www.fzronline.com/forum/viewtopic.php?f=8&t=7747
Hope that helps.
Re: Clutch Cable snapped
Reel Razor, beat me to it 
Too busy watching TV while typing didn't mean to repeat his advice.
Too busy watching TV while typing didn't mean to repeat his advice.