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FZ 16: Frequent clutch failures

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  • #1

    FZ 16: Frequent clutch failures

    Hi,

    I own a Nov, 2008 FZ-16. My initial clutch set lasted me the first 35K kms. After that i got a newer one installed (cork + steel plates).

    The first failure happened like this: depressed the clutch and engaged 1st gear, felt as if the wire strands broke. Then the clutch didnt have enough tension in it. There was too much a difficulty shifting gears. Went to a mech and got it tightened (no broken strands, just the wire was loose). Eventually, i got loosend again and then i got is replaced. This ran fine for 7K kms

    After 7K kms, i sent the bike to Bangalore for mods. There it was reported that the clutch is gone bad and was replaced with a new set (cork/steel plates & basket).

    Now, 2 days ago, i got the bike from Bangalore with the new clutch. Hardly rode it for 100 kms and the symptoms started again (trying to take off in 1st, felt like something broke, loose cable, retighten etc). No matter how much i retighten the cable, it always seem to get more loose. Finally I have run out of the adjustments. Bike is sitting at home, cant even ride it to the service station.

    Can you please suggest as to what might be the cause for such frequent failures?

    Any help is much appreciated?

    Also would be deeply indebted, if you could guide me to a compotent mechanic in hyderabad to get this issue checked.

    Thanks in advance !
    -AK
    Tags: None
  • #2
    Query approved.
    (Been There Done That) x 3.25

    Comment

    • #3
      What is failing? Clutch wire getting cut often or clutch plates/friction plates going kaput?
      Question - Do you engage the clutch when closing down the throttle or decelerating or when applying brakes?
      Skill is what keeps you on a Motorcycle
      Awareness + Skill is what keeps you out of harm's way
      ATGATT + Awareness + Skill means you might Live To Ride another day

      Comment

      • #4
        Ok am no expert on this matter, all i do is set my own freeplay settings. Anyways: you say that u tighten the cable and it comes loose again, now assuming that u are tightening the lock nut properly, can there be a problem with the threading of the adjusting and lock nuts? Did you check?

        I am suggesting this because once I had not tightened the lock nut properly and the clutch cable came absolutely loose while I was riding.

        Btw u can always up-shift without engaging the clutch if you know the right technique (I do this often enough and it is super-smooth all the time cause I have gotten quite some practice now) and while it is not recommended to down shift without engaging the clutch EVER, I have done that too but ONLY at VERY VERY low rpms. So its like if at 5th gear, the tacho shows 1500rpms, i can shift down without clutch and its not as smooth as upshift but the bike never stalls and I manage just fine without the clutch. Now this (downshift) method is to be used ONLY during emergencies but u should maybe try this and get the bike to service station atleast cause you definitely seem to be in an emergency right now..!!
        ---

        ~~Triplogs~~
        H G B | Ooty-Kotagiri-Sathy - Epic Marathon Ride | Yercaud | Kudremukh Tea Estates

        ~~~DIY~~~
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        Comment

        • #5
          Originally posted by sunilg View Post
          Query approved.
          Thanks Sunilg for the approval.
          -AK

          Comment

          • #6
            Originally posted by aargee View Post
            What is failing? Clutch wire getting cut often or clutch plates/friction plates going kaput?
            Question - Do you engage the clutch when closing down the throttle or decelerating or when applying brakes?
            The clutch plates are failing. The wire is not being cut and there is no problem with the adjusters not doing their job i.e. they keep the wire held without letting it slip by.

            I am unable to force the 'push lever' (not the push rod) too. It is stuck in there and when i try to push it with my fingers, it can move only a few mm. is very hard.

            Yes, i use the clutch all the time - while upshifting/downshifting. i do not engage the clutch when i think there would be enough speed left to continue without stalling in gear after the breaking operation.
            Last edited by asim.mohd; 04-05-2012, 11:18 AM.
            -AK

            Comment

            • #7
              Originally posted by plasmabhai View Post
              Ok am no expert on this matter, all i do is set my own freeplay settings. Anyways: you say that u tighten the cable and it comes loose again, now assuming that u are tightening the lock nut properly, can there be a problem with the threading of the adjusting and lock nuts? Did you check?

              I am suggesting this because once I had not tightened the lock nut properly and the clutch cable came absolutely loose while I was riding.

              Btw u can always up-shift without engaging the clutch if you know the right technique (I do this often enough and it is super-smooth all the time cause I have gotten quite some practice now) and while it is not recommended to down shift without engaging the clutch EVER, I have done that too but ONLY at VERY VERY low rpms. So its like if at 5th gear, the tacho shows 1500rpms, i can shift down without clutch and its not as smooth as upshift but the bike never stalls and I manage just fine without the clutch. Now this (downshift) method is to be used ONLY during emergencies but u should maybe try this and get the bike to service station atleast cause you definitely seem to be in an emergency right now..!!
              Thanks Plasmabhai. i need all the help i can get

              All the clutch wire adjusters are working fine.. i am sensing an issue with the clutch itself.

              seems I will have to do the clutch less shifting to get her to a mech/service center.
              -AK

              Comment

              • #8
                This forum thread is of some help. posting it here so that someone with a similar issue can have a look:

                stuck clutch release push-rod
                -AK

                Comment

                • #9
                  resolved

                  Hi,

                  Sorry for posting the resolution v late.

                  Got the push lever and clutch overhauled at Patny Motors, Begumpet. The mechanic did a good Job.

                  It's been >1000 Kms since the repair and bike is running quite well.

                  Thanks everyone for the replies !
                  -AK

                  Comment

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