Thread: Clutch cable issue in Yamaha Fazer 153cc

Hello Frens, not sure if any other FZ/Fazer owner is facing similar problem as I didn't find relevant post anywhere.

ISSUE: Inadequate clutch cable life.

Bought my Fazer on October 2010 and at around 8000 kms, the clutch wire snapped off while on the move. Fortunately I was able to pull over without risking anyone. The Yamaha service supervisor gave me road side assistance within couple of hours. But, I had to bear the cable cost (130) as it's a part which is susceptible to frequent wear & tear and is not covered under warranty (as told by the service supervisor). Now, at 14,000 kms the clutch wire snapped off again. Got road side assistance this time too and I was told to keep a spare cable underneath my seat in case I'm out of reach etc.

Now, about the way I handle my bike. I don't do much clutch holding like many do while braking. I use clutch only when I want to shift gears and some times have to do clutch riding in Bangalore traffic. I was riding HH Splendor (before buying Fazer) for about 30K kms and never had a problem with clutch mechanism. I explained this to the supervisor and he gave me a clear reason why it didn't cut in splendor but in Fazer. In Fazer, the cable is routed in such a way that it has to take several sharp bends to reach LHS of the crank case. Whereas, Splendor and most other bikes have their clutch cable terminated on the RHS of crank case and so lesser bends which automatically proves that there is more friction in Fazer design.

Since it appears to be a design flaw, I asked him if this is an issue faced by many other Fazer owners too, and the answer was YES. He himself has seen around 15-20 cases and escalated them to Yamaha design team (including mine) it seems. Looks like Yamaha has made a study and sent a redesigned clutch cable for field evaluation (which would suit our traffic usage). Will there be a total recall (which I'm not optimistic about) or replacement for bikes with issues (which is more likely) alone is not known yet.

Since, it's a matter of 130 rupees, I don't think many would have really bothered to pay for it. This post is just to give you a warning about the unreliable clutch wires. Check with the nearest Yamaha A.S.S. immediately if your clutch free play becomes abnormal (beyond adjustable limits).

Suggestions are very much welcome.

Query approved

Originally Posted by pdydeva

Hello Frens, not sure if any other FZ/Fazer owner is facing similar problem as I didn't find relevant post anywhere.

ISSUE: Inadequate clutch cable life.

Bought my Fazer on October 2010 and at around 8000 kms, the clutch wire snapped off while on the move. Fortunately I was able to pull over without risking anyone. The Yamaha service supervisor gave me road side assistance within couple of hours. But, I had to bear the cable cost (130) as it's a part which is susceptible to frequent wear & tear and is not covered under warranty (as told by the service supervisor). Now, at 14,000 kms the clutch wire snapped off again. Got road side assistance this time too and I was told to keep a spare cable underneath my seat in case I'm out of reach etc.

Now, about the way I handle my bike. I don't do much clutch holding like many do while braking. I use clutch only when I want to shift gears and some times have to do clutch riding in Bangalore traffic. I was riding HH Splendor (before buying Fazer) for about 30K kms and never had a problem with clutch mechanism. I explained this to the supervisor and he gave me a clear reason why it didn't cut in splendor but in Fazer. In Fazer, the cable is routed in such a way that it has to take several sharp bends to reach LHS of the crank case. Whereas, Splendor and most other bikes have their clutch cable terminated on the RHS of crank case and so lesser bends which automatically proves that there is more friction in Fazer design.

Since it appears to be a design flaw, I asked him if this is an issue faced by many other Fazer owners too, and the answer was YES. He himself has seen around 15-20 cases and escalated them to Yamaha design team (including mine) it seems. Looks like Yamaha has made a study and sent a redesigned clutch cable for field evaluation (which would suit our traffic usage). Will there be a total recall (which I'm not optimistic about) or replacement for bikes with issues (which is more likely) alone is not known yet.

Since, it's a matter of 130 rupees, I don't think many would have really bothered to pay for it. This post is just to give you a warning about the unreliable clutch wires. Check with the nearest Yamaha A.S.S. immediately if your clutch free play becomes abnormal (beyond adjustable limits).

Suggestions are very much welcome.

No such experience. My last one lasted 12000Km when I changed it according to the manual specs....The mech said it will last another 6K minimum.

Originally Posted by greenknight

No such experience. My last one lasted 12000Km when I changed it according to the manual specs....The mech said it will last another 6K minimum.

Thanks for the response. Good to know that.
OT: I don't see any factory recommendation to replace any cable after 12000 kms. Also, I don't think any manufacturer recommends periodic replacement of cables, but just to check and adjust free play. Yamaha recommends to replace spark plug, air filter, oil filter & lubrication of bearings at 12000th km and nothing more (unless anything is damaged/worn out).

Looks like you've a very little play or almost no play with the clutch lever. Check on that pls.

Originally Posted by aargee

Looks like you've a very little play or almost no play with the clutch lever. Check on that pls.

Thanks Aargee. But, I always make sure that the freeplay is as per factory recommendation.

YFS SVC guys recommend 12K replacement for cables as a safety measure...

Do you wash your bike too often? Due you live in a humid area? That might be a reason. Because I broke my acc cable due to rusting .

Originally Posted by greenknight

YFS SVC guys recommend 12K replacement for cables as a safety measure...

No wonder they recommended it, even though factory doesn't suggest the same

Originally Posted by Vishakh

Do you wash your bike too often? Due you live in a humid area? That might be a reason. Because I broke my acc cable due to rusting .

Well, in my case the cut wire doesn't look rusted

OFF TOPIC:
My Fazer also had starting issues. After a long drive, the bike wouldn't start and the starter will be completely dead. The battery was perfectly fine and all other electrical systems would work without any issues. Service people said it might be due to a loose contact of the battery terminals. After a 2nd opinion with another mechanic, it turned out to be starter capacitor issue.

Got the starter capacitor replaced under warranty.