FZR 600 Clutch, oil leak and service
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- Опубліковано 17 кві 2020
- The FZR clutch was getting a bit baggy after 45,000 miles. With the prospect of a road trip later in the year I take the current lockdown as an opportunity to change the clutch, as well as tackling a few other jobs.
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Just bought a 96 fzr600 for my first bike and I’m working on restoring it and getting it running. This video is invaluable and thank you for the work and detail you put into it.
Thanks, really appreciate it. Great choice of bike, you will love it. Thanks for watching 😎
Finally managed to pull my 93 into my garage to start tearing it down to get it running again and you're video's have been invaluable, thank you.
Fantastic, thanks, glad they have been of help. Check out the FZR restoration Playlist if you haven't already. 👍
I just bought a 1994 FZR600R Genesis, these videos are so amazing, thank you for taking the time to try and help fellow enthusiasts and bikers out!
No problem, glad you find them useful. 😎 Congrats on the purchase, they are fantastic bikes.
@@PhilOsGarage Got it all back together. New chain, new sprockets, new stainless steel brake lines front and back, jetted, carbs rebuilt, Micron exhaust system ceramic coated, new spark plugs and wires. New hand grips and clutch and brake levers. New rear sets as well. Went to go do the clutch, mind you this is my first time. I go to torque the Clutch Cover Plate on and one of the wells where the bolts sits, the bottom part snapped. I was having issues with my torque wrench so that is probably the cause or it was a mistake on my part for not trying to tighten the bolts in a real star pattern getting ahead of myself. Re-ordered a new one so we will try again when it comes in, I was hoping to be able to ride this weekend!@ Thanks again for your videos.
Incredibly helpful, thank you
You're very welcome!
A couple of things worth mentioning on your clutch replacement. When you remove the cover, given the age of these bikes, the gasket is likely to be hard and stuck to the surfaces so may come apart. You need to do a careful but thorough job in removing it all from the surfaces of both the cover and engine cases to prevent leaks. Also you will need a new gasket for reassembly. The second thing is that when you have removed the bolts and springs it's worth marking the pressure plate and one of the bolt holes. With 5 bolt holes there are 5 ways to orient the pressure plate when you put it back on but only one position is correct to allow the pressure plate to be fully seated. The other 4 ways don't allow it to seat properly in the splines of the clutch boss so it won't put pressure on the clutch plates, thereby giving you clutch slip despite installing new plates.
Yes, any hint of old gasket will cause leaks. Some people use a little gasket goo, which if used sparingly is not a problem, fortunately the gasket faces were cleaned thoroughly when i restored the bike, so everything sealed OK with a new gasket
Hi Bill, had an essential journey to do today so took the bike, the new clutch feels soooo good. What I didn't mention is that it's worth checking the basket for wear on the fingers and de burring if necessary, it helps the plates slide smoothly. I'm so used to doing it I forgot to mention it on the video. Most tend to be OK, but while it's apart it's worth checking.
Hola , amigo. Me gustó mucho tu video como tu explicaste todo. Estoy pensando comprarme una yamaha y esto me va ayudar muchísimo. Muchas gracias por tú video. 🤓👍🏍
Muchus gracias. Es un bueno moto, mi amore 600cc classico. Disculpe, mi Español es no bueno!
Very Helpful, thank's a lot from Germany.
Thanks, glad to hear that it was useful 👍
One other tip I didn't mention in the video, it's recommended for the steel plates to go in with the radiused edge inwards to ensure they engage smoothly.
@@PhilOsGarage Actually i have This Problem, i buy a new Springset hope it's gettin smoother. The Basket it's actually not in good condition too, try to fix it....
found you on another channel...luckily...great channel mate...subbed
Thank you, appreciate it. 😊 Got something good in the pipeline, as soon as we are back out.
Just had a look at yours, subbed back, you're making great videos 😊
What brakes did you install on the bike? Looks like you have nice 4 pot brakes compared to my singles.
The clutch on the FZR can be weak, but that should keep it going.
My FZR is a 91, H plate, but it is running the separate oil cooler. When I got it 14years ago, it was a non runner. The chain had snapped and took the water pump out. The engine casing was damaged, but welded. I got it running, but was leaking oil badly. I bought an engine from a breaker, noticed a few differences, but fitted it. It wouldn't run. I discovered that the breaker had sent me a later Foxeye engine. It has a different ignition system.
I got another engine, but it turned out to be an earlier engine, so it hadn't a spin on filter. It runs well now. I got a NOS set of carbs on Ebay for £100 and it improved the MPG and running.
I bought a Foxeye with a wrecked engine, another broken chain! The water pump was a car fuel pump! Used the engine I had, it turned out to be a really good, low mileage engine.
So, I have both models, but prefer the older one.
When we built our race bike we looked at various options. It was the notoriously weak and unpredictable clutch which ruled out the FZR 1000.
My fzr's clutch starting to slip now
Ooo nice tip re the oil cooler! I don't have the same bike, or even the same type of bike, but this was interesting to watch! :-)
Thanks dude. Most oil coolers will have a hex.. Many have been damaged by not using it.
@@PhilOsGarage I wonder if radiator do too?
Not ones I've seen. Usually the only threaded part would be a fan switch (temp senders are usually in the thermostat housing and never in the radiator). It's feasible there may be a hex there, but I've not seen one.
Funny what you said about the torque wrench probably not going low enough . I torqued mine to the factory settings and snapped a bolt lucky it was the bolt and not stripping the threads . Good job done you will have quite a few years of use out of that . Cheers
Thanks, yeah, some of the parts are supprisingly small. I reckon the FZR will be on the road for many years yet. If only I'd have taken some video when I bought it, it was one foot in the crusher.
i have 2 precise torque wrenches and i dont use them for this reason, factory specs must be only for new parts assembled at the factory. Eg. 40Nm for a oil plug with a rubber or nylon gasket is way too much. With aluminum its much better to just go by feel.
@@PhilOsGarage do you know the torque spec for the clutch plate springs I've looked for weeks now and can't find it
Nice video. Have a purple 93 here in the US i've owned for approx 25 years. Replaced the original clutch cable a few years ago after having let the bike sit for 10+ years (the soft front suspension ripped the handlebars out of my hands during emergency breaking to avoid an animal and almost wrecked...scared me off from riding). Anyway, replaced my clutch cable last year with an aftermarket and it snapped the 5th time I squeezed the clutch. Ordered a OEM cable and its held up fine. Took my clutch disks out to look for biinding but your video and comments are making me wonder if replacing the clutch basket might make the clutch lever squeeze a bit easier. Has anyone else had a stiff clutch pull or do you find it comparable to other bikes?
Thanks for watching. The FZR clutch is quite small, so they use fairly stiff springs which definitely makes it heavier than the CBR for example. A worn basket often shows up as a notchy movement rather than heavy. Both my CBR 600 and my Benelli have lighter clutches than the FZR, it's just how they are.
I myself have a 94 fzr600r and loved the video. Have you had to service the stator? If so what level of difficulty did you find?
Hi, thanks for watching. Stators do not require any servicing, they either work or don't. They can be checked with a multi meter if you are having charging issues, however, the regulator rectifier is more likely to be the cause.
Just found your channel looking for brake rebuilding advice and subscribed. I just bought rolling 90 fzr600 and a stripped fzr400 frame and swingarm. Looks life everything except the engine needs going through. Wish me luck.
Hi, thanks for watching. There is quite a bit of commonality between the 400 and 600, and they are very good bikes to work on. Good luck, it will be a great project. 😎👍
One tip, if taking the engine out or putting it into the 600 frame, you need to slacken off the swing arm pivot bolt, or it won't go in (not sure if this applies to the 400 or not, but I suspect it does). Check out my FZR restoration Playlist.
@@PhilOsGarage I had the 600 motor on 2 x4's and dropped the stripped 400 frame down on top of it. nice and easy. i than installed the suspension but now i have to source a bunch of missing parts from ebay ,craigslist and letgo. The project a slowed a bit as no one has some crucial components, but there are some local breakers that i havente contacted yet.
There is a great breaker in Netherlands called Boonstra who ship worldwide. The parts are top notch and tested, they are more like a dealership than a breakers - clean, professional and polished, I highly recommend them.
@@PhilOsGarage thanx. I ordered some parts from them and they shipped in about a week... From the Netherlands to California!
Hey I have a 93 FZR 600 and I change the clutch and Clutch cable and it won't go into gear now....with the old clutch it went into gear just fine. Any ideas why?
It sounds like the clutch isn't disengaging. Check cable adjustment first.
Great job!!! I was wondering something and i hope you could help! I did a rocker cover gasket change on my 91 fzr600 and it was tricky but it went on fairly well but after i tightened it down i noticed a corner of the gasket was in a bit but although its not perfect it seems it will hold oil, do you think if i fill the gap with gasket maker itll be okay?? I used gasket maker to help hold the rubber one in place while i worked so i dont know if loosening it and adjusting it would be safe to do or if filling it would be okay! Thanks!
Hi, thanks 😊. Ideally I'd pull the cover and re seat the gasket, but if it's not leaking there shouldn't be any harm is just filling it in..
@@PhilOsGarage you dont think loosening and readjusting could cause an issue even if i used gasket maker to hold the gasket in place while i fit it? The engine is out of the bike so i don't know of itll hold or not yet so im nervous haha thanks for replying and helping it means a lot!
hey i got a new crank case cover and when i tighten it down it doesn’t turn over
Hi, sounds like it's the wrong cover. Take it off and look for evidence of it touching things. Hope you get it sorted. 👍
where you found that oil lines, they look new cant find them anywhere
I had trouble finding them too, eventually finding a good set at a breakers in the Netherlands. Your options are either making them yourself with dash 6 line, or searching for a good used set. Thanks for watching 😀
Quick question Phil, where abouts do you get all your parts if you don't mind me asking?
Hi Micky, the seals for the cooler came from yambits, the clutch and oil filter from wemoto. The clutch cable was via ebay. I'd definitely recommend yambits and wemoto. The oil cooler lines came from Boonstra parts in Netherlands, who were also excellent.
@@PhilOsGarage thanks very much Phil! Great videos, plenty of information! Keep up the good work 👍
wTF kind of FZR600 is this? That oil cooler and filter are not on my 93. o_O either way, good vid, but jeeez now I'm wondering what else is different. I've had mine for over 10 years, so who knows before that, but it's been running perfectly since I refurbed it then though I just found a peanut cover leak, so looks like i'll be correcting that soon.
Hi, thanks for watching. It's a 1990 3HE for the European (UK) market. There seems to be no logic as to which markets got oil coolers and which didn't. If yours is a US market bike I don't believe they ever had them.
Awesome video, just bought one! EDIT: I'm surprised by the quality of the external mic and editing. Again; awesome video! You could very well cut the video, and repost the clutch part, for far more hits with the title: "How to replace a Yamaha sports bike clutch". Or so... :)! Cheers
Thanks, they are very good bikes, very agile and great fun on twisty roads. You will love it! 😎
@@PhilOsGarage Yeah, I've bought the FZR 600R - Year; 1994. It's an amazing sports bike. It stood still for 1 year, and the RMP's don't go well until 4K, then it's a beast.
So I need to redo the jets, especially the stationary-jets, because those are for the range 0 till 4K rpm.
They don't have an abundance of low end power, so don't spend ages chasing gains which probably aren't there. Thanks for the comment re: mic, I use a lavalier clipped to my shirt for these videos with a Tascam DR-05 voice recorder, it works well in this sort of situation.
Can you show how to replace clutch cable
The clutch cable is pretty straightforward. Wind the handlebar adjustment fully in, then on the sprocket cover, remove the rubber plug. Under the plug there is a lock nut and screw. Undo the lock nut and back the screw off a couple of turns.
Remove the sprocket cover, and unhook the cable, then unhook from the handlebar end. Take the fuel tank cover off, and guide the cable out.
Fit the new one in a reverse of this process, to adjust firstly adjust the sprocket end by screwing down the screw until resistance is felt, then back off 1/2 turn. Lock down, and make the final adjustments at the handlebar end.
@@PhilOsGarage thank you I'm 15 and bought a 1991 fzr600 and trying to build it back up on my own this was helpful, I bought the bike and there was no clutch cable so I had no idea about the plug
Where did you buy the parts in this video? Especially the clutch disks
Hi, I use two main suppliers, Wemoto (who I purchased the clutch from) abd Yambits. Both are based here in the UK, and both are excellent.
Hi can I use 10w40 magnatec a car oil on fzr1000 1989..
No, absolutely not. Car oil doesn't have the additives a wet clutch requires
@@PhilOsGarage Thank you sir👍
@@PhilOsGarage Thank you so much 👍🤝