FZR 600R GENESIS CLUTCH

aaronneary · Two Stroke Sniffer Joined: 27 Jan 2013 Karma :

Hi, Was coming off the motorway and the clutch on my bike completely failed. Got the bike home took it apart and realised the push rod was broken. Made a new rod at work and reassembled. But there is still no tension on the clutch at all. Tried adjustment and at a complete loss. Can anyone put me on the right track. Thanks
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FZR 600 R GENESIS(commute) - ZZR600 (nice weather)

base · Trackday Trickster Joined: 09 Nov 2004 Karma :

Have you had adjuster sprocket cover off? as really there is not much to go wrong with them, how did the push rod fail any pictures, might help understand the cause of the problem a bit better.

I know the cable takes a tight route, I assume thats intact, is the new push rod long enough?

aaronneary · Two Stroke Sniffer Joined: 27 Jan 2013 Karma :

The cable is intact as it still operates the mechanism that would move the push rod. I made the rod at work today and made it to the exact size of the one that i removed. Don't know if that helps.
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FZR 600 R GENESIS(commute) - ZZR600 (nice weather)

base · Trackday Trickster Joined: 09 Nov 2004 Karma :

you say you made a new rod does it incorporate the ball bearing, that sits onto the pressure plate end,

Here is a link it may be of some help?? there is loads of fzr600 info.

https://www.fzrarchives.com/ipb/index.php?showtopic=56357

its such a simple set up rod, ball bearing short push rod onto pressure plate, if memory servers me correct.

base · Trackday Trickster Joined: 09 Nov 2004 Karma :

here is a diagram of the set up

https://images.cmsnl.com/img/partslists/clutch_bigyau0029c-8_fa94.gif

Vincent · Banned Joined: 16 Oct 2006 Karma :

You know most of them rods have hardened tips?
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69chris · Trackday Trickster Joined: 10 May 2011 Karma :

never having one break myself id be wondering what caused the push rod to break in the 1st place Confused

when you say the clutch failed completely do you mean you had no drive or that the c/lever simply didnt do anything ?? Smile

base · Trackday Trickster Joined: 09 Nov 2004 Karma :

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Ignore me.
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69chris · Trackday Trickster Joined: 10 May 2011 Karma :

If adjusted up too much they end up turning with the engine and this can apparently cause them to fail, so I have read, on a FZR forum.[/quote]

yep i can sort of agree with that, well, i can agree that might 'burr' the ends of the p/rod,
but that would surely assume that the b/bearing was missing and the clutch was adjusted so tight that it must have been slipping at some point Confused

have had loads of old Z's that have the same set up and never had a problem with pushrods breaking, had the 'worm' lifter fail, had the clutch basket nut come undone and the clutch try to eat its way out through the cover, just never broke the p/rod Laughing