Noob with clutch trouble

[cobraguy]

Hi all I'm a mechanic and my son recently got a 93 FZR 600 RAC. I ride criusers so his is way faster then I need to go. He recently started having clutch trouble. He's getting a high pitch squeal from the clutch side of the motor when the lever is pulled in. The clutch looses adjustment in a short time. I've got the manual thanks to pdftown.com and the parts breakdown looks like he's wearing out the pushrod or cover or both. I haven't opened the case yet. The other possible culprits I can see on paper are the cable streching or the pushrod and pushrod activator thingy that the cable connects to by the front sprocket. None of these would explain the squeal though. He has also complained that the clutch lever is very stiff. I'm thinking it has a high performance clutch with stiffer springs maybe since the motor has been tweeked. Anything special I should watch out for when I tear it down. Thanks in advance for any input and recomendation for replacement clutch parts.

[shredex]

maybe the clutch needs to be lubed?
the cable needs to be lubed for easy movent threw the cable tube.
have you tried adjusted the clutch at all?

[cobraguy]

Yah I took it for a short fast test ride today. I had previously adjusted it at the pushrod. By the time I was on the return side of my testride I had to adjust the cable almost all the way out. Whatever is wearing out is going away fast. From adjusted to gone in three 4way stops, 2 lights, and 1 offramp. There's no adjustment left at either end of the cable now.

[reelrazor]

Hi all I'm a mechanic and my son recently got a 93 FZR 600 RAC. I ride criusers so his is way faster then I need to go. He recently started having clutch trouble. He's getting a high pitch squeal from the clutch side of the motor when the lever is pulled in. The clutch looses adjustment in a short time. I've got the manual thanks to pdftown.com and the parts breakdown looks like he's wearing out the pushrod or cover or both. I haven't opened the case yet. The other possible culprits I can see on paper are the cable streching or the pushrod and pushrod activator thingy that the cable connects to by the front sprocket. None of these would explain the squeal though. He has also complained that the clutch lever is very stiff. I'm thinking it has a high performance clutch with stiffer springs maybe since the motor has been tweeked. Anything special I should watch out for when I tear it down. Thanks in advance for any input and recomendation for replacement clutch parts.cobraguy

It may be, due to improper adjustment in the past, or low lube levels (engine oil lubes clutch) that the clutch pushrods(two-which are separated by a ball bearing), running through the trans input shaft have either become scored..or even welded themselves (one or the other) to the ball.

This would cause your squeal while clutch 'loaded'. This setup is the equivalent of an automotive throwout bearing. The ball between the pushrods allows the speed of rotation to be reconciled between the two pushrods.

This used to be really common...I think less so now. And, someone may have put waaay too strong of springs in the clutch pack-which really isn't necessary unless SERIOUS hp increases are being made.

And, the mushroom shaped pushrod (index part #9 1WG-16356-00-00 ROD, PUSH 1) that works against the pressure plate may have scored the pressure plate(index part # 6 2TK-16351-00-00 PLATE, PRESSURE 1 )

Inspection is easy. Let the bike sit after warm for 10 minutes on the sidestand and you will only lose ounces of oil (if that ). The clutch pack itself is relatively simple/straighforward. You know the drill. Look for witness marks...push the pushrods out..there should be a ball in there...it may be a ground down pebble at this point (would explain the rapid adjustment needs).

[cobraguy]

I'll rip into it when I get from vacation. I do know the engine was built by a local race builder that has ties with team Yamaha MX stuff. So its benn done right. His recently retired 250 Ninja was fun quick this thing is scary fast. I'll take some pics of the job and share what I find. Thanks for the input and commoents. It sounds like I'm looking at what you described with the pushrod bearing turning to dust. If that is the case we'll probably do an oil change just to be sure its all clean and free of shrapnel.

[shredex]

I'll rip into it when I get from vacation. I do know the engine was built by a local race builder that has ties with team Yamaha MX stuff. So its benn done right. His recently retired 250 Ninja was fun quick this thing is scary fast. I'll take some pics of the job and share what I find. Thanks for the input and commoents. It sounds like I'm looking at what you described with the pushrod bearing turning to dust. If that is the case we'll probably do an oil change just to be sure its all clean and free of shrapnel.

yea, and give your sprocket cover a good cleaning...youll be suprised to see how fast that thing builds up with gunk.
make sure nothing gunked up in the clutch cable mechinism than pushes the push rod