My son has a 1996 yamaha fzr 600. Tring to replace the clutch cable but having problems. Looking for diagram

Question

any free downloadable diagrams or service manuals?

Answer 1

-On the L side of the engine, behind the triangular cover, is where the clutch cable connects to the engine. The round cap is for clutch adjustment.

-To change the cable, remove it from the clutch lever (handle bars).
-Loosen the lock nut and screw the adjuster all the way in.
-Line up the slots on the nut & adjuster with the slot in the pearch (the lever is attached to the pearch).
-Grab the cable with one hand and squeese the lever in with the other.
-Pull on the cable as you're letting out the clutch lever. Remove the cable from the lever.
-Remove the cover on the engine and remove the cable from the push lever.

-With the old cable still on the bike, route the new cable the same way. Might have to remove some stuff like the tank.
-Attach the new cable to lifter lever on the engine. Re-install the cover.
-Attach the cable to the clutch lever.
-Line up all the slots again.
-Hook the cable on the adjuster nut.
-While holding the cable, pull in the lever.
-Pull the cable while letting the clutch lever out, to get the cable in the adjuster.

-To adjust the clutch - Remove the cap on the engine.
-Loosen the lock nut and back the adjuster out a little.
-Turn the adjuster in till it just touches and back it out a 1/4 turn. Then tighten the lock nut (you don't want any tension on the lifter. You'll burn out the clutch).
-Turn the adjuster at the clutch lever so there's 1/8" (4mm) free play (no tension on the cable).
-Tighten the lock nut. It's better to have to much free play, than to little (make sure the slots don't line up, so the cable won't fall out).
-Remove the old cable and put the bike back together.