Question about 2011 Yamaha FZ16

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FZ16 adjust clutch lever free play - 2011 Yamaha FZ16

Posted by Anonymous on

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  • Yamaha Master
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Hi, Anonymous for this scenario you will need your service/owners manual if you can't find the first and best tool you ever bought for your Yamaha, despair not, for a mere $0 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
How to adjust clutch engagement point
How to adjust motorcycle clutch cable
Yamaha FZS FZ16 Service Manual pdf
OEM parts for Yamaha
Yamaha FZ16 User Manual pdf

Posted on Nov 27, 2016

4 Suggested Answers

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Posted on Jan 02, 2017

rselvy
  • 83 Answers

SOURCE: clutch adjustment 2004 v-star 650

Sir,
The bike you are working on has a couple of way to adjust the clutch. Obviously the adjuster on the handlebars would be the first place but actually there is an adjustment on the other end of the cable that has a locking nut on it. You will need to loosen the nut that locks the cable and there should be another nut on the other side of the cable that you can tighten. As you tighten the nut it will take the free play out of the cable.
There is another adjustment on the inside of the clutch cover, it is on the clutch hub. The adjustment for this would be done by removing the clutch cover to access the clutch hub. On the outside of the hub there is an 12mm nut locking down a 6mm adjusting screw, the screw is adcually the first source of adjustment on initial assembly.
Let me give you the breakdown of how this works, your clutch mechanism has the hub adjustment, a ball, and a push rod that goes through the primary output shaft of the transmission. Then it goes to the actuating arm where your cable connects. The reason I'm telling you this is because often the ball in between the hub adjuster screw and the clutch push rod becomes welded to the push rod or it will actually start to come apart. When this happens your clutch adjustment goes away and you have no adjustment available through the cable or the clutch lever. Should this be your case I would recommend you take the clutch cover off, (be sure to drain the oil first), remove the six 10mm nuts securing the clutch hub, (this also holds the clutch springs in place), then you will have access to the push rod and the ball. You may have to tilt the bike over on the right side to get the push rod and ball to come out.
When you go to reassemble the clutch make sure all the adjusters are loose so you can adjust the clutch in the following sequence:

  1. Assemble the hub and secure the springs. You want to adjust the hub screw first. Gently turn the screw in until it contacts the ball, then back out the screw 1/4 turn. This prevents the ball from welding it's self to the ball and plunger.
  2. Install the clutch cover and the clutch cable all the way to the lever. You will first adjust the free play out at the base of the cable so you have maximum adjustment at the lever.
  3. Adjust the lever so you have 1/4 of free play at the lever.
This will give you a properly adjusted clutch that has lots of adjustment at both the handlebars and at the base of the cable.

Good Luck! This is a DIY job, you wont need to take the bike to the shop if you are able to do any routine maintenance. Should you have to remove the clutch cover you will need to replace the right side, (clutch cover), engine gasket. If you take it apart I would recommend replacing the ball if it has any signs or wear, it will be blotted, this is a very cheap item that can cause much grief.

Let me know if you need any further assistance.

Regards,
RSelvy

Posted on Jan 02, 2009

  • 3567 Answers

SOURCE: 1977 ty 250. locks in gear. 1,2,3, or 4 th. and cannot be changed

You have nothing to loose. Try the adjustment. Try it a couple of times. Chances of a bent shift fork are 50/50. Drain the oil and remove the right side casing, Look at the shift mechanism. Is anything loose or a spring missing? Remove the shift shaft. Is the shaft bent?

Pleas rate this solution. Thanks!

Posted on Apr 05, 2009

bazzz7071
  • 338 Answers

SOURCE: 2004 FZS 1000 Clutch slipping problem.

Sounds like the friction material bonded on the friction plate are coming off, time to do a clutch job.

Posted on May 25, 2010

Testimonial: "Thanks. It'll be stripped on Thursday for a look."

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Clutch is slipping


The clutch friction plates may be worn out.

The clutch adjustment is likely way out in any case. You will need to go into the inspection (derby) cover and adjust the clutch and the cable adjustment will have to be done at the same time.



Slide the rubber cover off the cable adjuster. Then holding cable adjuster with a one half inch wrench, loosen the jam nut using a nine sixteenths inch wrench and back the jam nut away from the cable adjuster and then move the adjuster toward jam nut to introduce a large amount of free play at hand lever. THEN using a T27 TORX driver, remove the five TORX screws with washers to remove clutch inspection cover (derby cover) and seal in the primary cover (unless it has a gasket as aftermarket or Screaming Eagle covers will have in which case remove the gasket). IF the screws are very tight use a spring loaded impact driver with the correct T-27 TORX bit and a suitable sized hammer to shock them loose OR heat them with a hot air gun (sometimes people also put Loctite on the screw threads which then may need heat to break down this locking compound). THEN using an Allen key in, and to hold, the adjustment screw and a wrench on the locknut loosen the locknut and then turn the adjusting screw in or clockwise until resistance is felt (to take up all free play and lightly seat the adjuster to the clutch push rod but no more) and then activate the clutch lever to ensure that the clutch release balls are seated in the ramps. THEN back off the adjusting screw one half to one full turn. THEN holding the Allen key and adjusting screw so neither can move anymore tighten the locknut to 72-120 in-lbs (8.1-13.6 NM). THEN squeeze the clutch lever to maximum limit three times, to set the ball and ramp release mechanism. THEN replace the cover seal or gasket if it is very old, deteriorated or etc. and verify that the seal is fully seated in the groove of the cover and if there is a gasket make sure it is facing the correct way i.e. with the rubber sealing surface towards the primary cover and the triangulated screw hole to the top. THEN using the T-27 TORX driver, install the five TORX screws and washers to secure the clutch inspection cover in place and tighten the screws in a crosswise pattern to 84-108 in-lbs (9-12Nm). THEN move to the cable adjuster and turn the cable adjuster clockwise away from the jam nut until all of the slack is eliminated. THEN pull the clutch cable ferrule at the hand control end of the clutch cable at the hand control lever bracket away from the clutch hand lever bracket to check the free play. You need to obtain 1/16 to 1/8 inch free play between the end of the cable ferrule and the clutch hand lever bracket i.e. while you are pulling the cable away from the clutch lever mechanism bracket there should be a space or freeplay of 1/16 to 1/8 inch or in other words if you can pull the clutch cable away from the clutch lever bracket that much you have the correct lever free play, so turn the cable adjuster as necessary to get this amount of free play between the end of the clutch cable and the clutch lever bracket on the handlebars. After you have adjusted the cable so that you have this free play then hold the adjuster with a 1/2 inch wrench and using a 9/16 inch wrench, tighten jam nut against cable adjuster and then pull the rubber cable adjuster cover over the cable adjuster mechanism. THEN place the spring washer over the lower inside hole of the left footrest support with the concave side of the spring washer facing the support flange. These cable adjuster instructions are for stock HD clutch cables as aftermarket cables will be somewhat different to adjust BUT the idea will be the same.

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1 Answer

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Adjust clutch pushrod adjustment (in center of clutch pressure plate), and adjust clutch cable free play.

Over time with use, a clutch cable will stretch, causing excess clutch lever free play.

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set it for 1/8 inch free play at the clutch lever, at the BELL.

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1 Answer

How do I tighten the tension on my clutch lever? My clutch isn't pulling at the lite.


Check your owners manual under maintenance for a description of how to adjust clutch lever "free play".

There is an adjusting knurled nut or adjusting nut (looks like a small sprocket) at the clutch lever... turning it clockwise will decrease the tension.. you probably need to turn it anti clockwise..Toward you as you sit on the bike to increase the tension.. remember there is only so much adjustment available... before you will need a new clutch.. Tinkering with this adjustment a few times in the driveway should help.. up to a point.

If you can't take up the slack this way.. you will have to loosen the lock nut at/near(the one at the end furthest from the termination point) to the the clutch and adjust (the adjusting nut is the one closest to the termination at the clutch) it at that end of the cable.. turn this adjusting nut toward the engine to decrease free play or tighten.. or away from the motor/anti clockwise to provide more free play) then readjust the lever end.. you basically want to remove the slop from a wearing clutch and stretched cable.

Nice bike.. enjoy.. ride safe

Best of luck

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2 Answers

My rpm turns higher but my speed still remains the same.


Sounds like you have a slipping clutch. You can check your owners manual for the proper clutch lever free play. A quick check would be to see where you are starting to engage the clutch or friction zone. With the bike warmed up and running, shift into 1st gear and then start to slowly releash the clutch lever. If the clutch does not start to engage until the lever is 80% released, then you can try adjusting the clutch lever free play. You can do this simply by sliding the rubber cover from the clutch lever. If the cable end is showing a lot of threads then you can loosen the larger lock nut, a serrated looking wheel with a slot in it, and give the cable end a few turns in. Lock in the lock nut and start the bike and see if the friction zone is catching earlier. Try adjusting to get it to catch within the middle of the travel. Once you feel you have the clutch adjusted, give it a road test to see if the engine will not rev higher without a corresponding increase in motorcycle speed. The owners manual will give you a precise range where the clutch lever free play should fall, usually measured from the end of the clutch lever. If the clutch seems to be adjusted properly, then a worn out clutch could be the problem.

Good luck.

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1 Answer

Honda nifty bfifty clutch slip, how to adjust or is it oil filled centrifugal clutch, if so how do u fill


Hello David?
Motorcycles have what is called wet clutches. The clutch is bathed in the engine oil(crankcase oil ) To ck the adjustment, squeeze the clutch lever enough to take up any slack. There should be at least 1/4 in freeplay. If no free play the clutch will slip. Too much free play and the clutch won't dis-engage.after verifying free play, Take this part with serious thought. Wet clutches do not like motor oil. It causes the clutch to slip. So, If you have changed oil or have added any and it was not motorcycle engine oil, It is more than likely your problem. You will need to drain the oil and filter and put the right type into the engine. The clutch has np separate oil supply. Lever adjustment should be at the clutch lever clamp. Now what is this 50/50? Good Luck-
Ned

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1 Answer

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