Yamaha FZR600R (Fox Eye) Starting/Gearbox Problem?

[robmorris]

Howdy

I recently purchased a FZR600R 'project bike'

It didnt start when I bought it but today ive had the tank off and emptied/cleaned it out.

Checked the fuel lines and the carbs and all seemed OK to me (Im not a 'proper' mechanic)

Cleaned the K&N air filter and put it all back together with 5 litres of fresh fuel..

Whilst doing all this I had the battery on charge.

I finally got her started but she would only start and keeping running with the clutch pulled in?

Whilst in Neutral (And the neutral light on) when I release the clutch lever the bike cuts out?

Also whilst running whilst in neutral and the clutch lever pull - I kick down into 1st and it cuts out?

It also doesnt seem to be able to get into 2nd/3rd/4th/5th?.. Just Neutral and 1st (Where it cuts out!)

So whats the opinion?

Cheers!

[dungbug]

Duff side stand switch? Clutch plates could be stuck together/worn out, more so if it's been laid up for a while.....

[robmorris]

Thanks - Even with the clutch handle pulled - when I select 1st it does jolt forward slightly whilst cutting out?

[robmorris]

Some further analysis...

So she starts normally now. Whilst in Neutral, kickstand up and me not touching the clutch.
If I now put the kickstand down she cuts out.. UNLESS I pull the clutch in and she will stay running with the kickstand down.

So back I am on the bike whilst its ticking over and I pull in the clutch and select 1st gear. She doesnt stall out but she starts to gently pull forward.. I can pull it back but she wants to continue pulling forward..

I wonder if I have 2 issues?

1 - Sticky/Stuck Clutch
2 - Faulty Clutch and/or Kickstand switch

[Mysteriass]

The FZR seems to possess a fairly simple Yamaha clutch

Are you certain your clutch issue is not just a matter of adjustment in the cable and/or clutch housing?

If you just need to adjust the cable more, that's easy. First, loosen the adjuster and the hand lever. Then, remove the lower left fairing. On the front of the sprocket cover there's a round black rubber cap. Remove it. Under it you'll have a, I wanna say 12mm, nut; loosen it. Turn the phillips screw until the slightest bit of resistance is felt. Turn it out again and tighten once more until the slightest bit of resistance is felt, then back out a 1/4 of a turn. Tighten the nut without moving the screw, check for free play at the hand lever, adjust as needed. You may wann give it a try while the fairings off. The first time I did this I tightened to much and had to pull it all off again. -- www.fzrarchives.com/fzr600/work_bench/the_clutch.html

That's the first place I'd start. The last guy who had this bike may have effed this process up and wasn't arsed to get the clutch cover back off and sort it out.

If that doesn't work, take a look at the pushrod. Be careful with the seal. Make sure it really is a pushrod and not a bent nail, been there, done that .

Possible interesting link: www.fzrarchives.com/ipb/index.php?showtopic=42259&st=0

[robmorris]

Thanks Mysteriass - that link certainly raised and answered a question and hopefully moves me closer to a resolve!

The following question was asked on the above link

--
Does the clutch function?
With engine off, can you push the bike in gear (any- gear2nd, 3rd,4th) with the clutch pulled in(disengaged)?
While pushing ,engine off, in gear, with the clutch in can you let the clutch out and have the rear wheel lock up or turn the engine over?
--

So I put my bike in 2nd, didnt touch the clutch and the rear locked up.
I pulled the clutch and it still locked up..
So my clutch is not working?
I then adjusted the clutch (at the handle) to the max and tried again.. This time I could wheel the bike - albeit just about on the limit of locking up.

So maybe the clutch cable has stretched or possibly requires adjustment at the clutch end?