FZR 400 3TJ clutch and adjustment

[Simo]

good afternoon,

looking for a bit of help/advice about my fzr.

im not sure wether my clutch has gone or if it just needs adjusting so the 2 problems i have got are,

(1) how do i adjust the clutch cable?

(2) how do i replace the clutch if it has gone?

im not a complete novice, i do work on my own car so i know enough to have a decent stab at it, the only problem is they dont do a haynes manuel for it so i have nothing to follow. also if anyone knows of a good reliable manuel or if there are any good threads on the fourm (i had a quick search but didnt find anything) then if you could post them up it will be much appreciated

[Evilchicken0]

Evening...

In the General Section in the sticky thread at the top there's "manual downloads" but try this one http://www.rampant-racing.com/product15.html" onclick="window.open(this.href);return false;

Ok there are a couple of things
firstly take the front sproket cover off from the left of the bike you'll need to take off the gear change from the splined shaft, you might want to put some tippex on it so you know where to put it back. You'll need to give the cover a good jiggling to get it off.
Give it all a clean. The clutch is worked through a rod under here and the mechanism picks up all the old chain lube and much which can make it stiff. A bit of paraffin on an old paint brush then a bit of grease on the round thing.

The cable is adjusted up by the lever -slacken the big wheel and then screw the adjuster out to take the cable slack and then do up the lock wheel.

See if that's made a difference.

If the the bite point is still to close to the bar then (with the sproket cover on) remove the big black bung on the sproket cover. You'll see a screw with a lock nut. Undo the lock nut unscrew the screw and then do it up until you feel the resistnace . use a socket with the screw driver through it to do up the locknut while holding the screw still. ride it again because this is easy to get wrong and the clutch will slip if it's to tight.

Welcome to the site - you've bought a great bike :)

[Taggyd]

if it is totally knakered its dead easy to change the plates, you'll need to drain oil to do it propa! then whip off the clutch cover, undo springs (5 i think) slide out plates, making sure you remember the order of friction and drive plates replace, reversal of above then adjust as mr evil says! lots easier than a car clutch!

[Simo]

thanks for the reply, the manual has been a great help.

when i looked at this at the weekend under the front sprocket cover there were two little lugs (which snapped off once i put a socket on the locknut, which is bloody tight!) what were they for? and will it work without them? also once i loosen off the lock nut and adjust it what is the 'perfect setting?'

as for changing the plates that looks straight forward, im going to take it to bits over the weekend and see how much meat is left on the plates before i replace them.


cheers again for your help

[dobbslc]

Hi Simo & welcome
It sounds like you might have undone the large front sprocket nut, that has a locking washer on it with two lugs you bend over to secure the nut. You will need to replace this just in case or if your lucky it will have another "tab" you can use.
The clutch adjusting nut is the small one with a screw inside it in the cover I think (about 10mm) undo this and back off the screw then turn it back in untill you just feel it just touch down then back it off half a turn.
The idea is to get a bit of free play on it so when things get hot it can all expand a bit and not cause the clutch to slip.
I hope this makes some sense as I'm very tired now!

[Simo]

had a look at the adjusment on the sprocket cover yesterday (because i was really nice weather so it was rude not to try and fix it!) and the bike us usable again now, i am going to ride it for a couple of weeks and see how it goes and after that i am going to take the clutch out and see how much is left on it because i plan on going to france on it in july and thats the last thing i want to go!

cheers for your help

[Evilchicken0]

sounding good so far