FZ6 Mini Mod – Fixing The Heavy Clutch

My Yamaha FZ6 S2 has been a great weekday commuter workhorse, yet with enough beans for some weekend fun. However, it’s not without issue, in particular the clutch. Firstly, it’s very heavy on the hand, to the extent I was getting hand ache in the first few weeks of ownership and was convinced it needed a new clutch cable (which changed little!) Secondly, the clutch bite point is way out on the lever, with little distance before fully released, even when all correctly adjusted with free play to spec. This all adds up to clunky gear shifts that you can never quite smooth out, you just can’t get throttle blips timed nicely with the point of clutch engage.

Recently I stumbled across a simple mod that promised to improve the heavy FZ6 clutch, which entails swapping on the lower clutch push lever from an MT07. This is the lever at the lower end of the clutch cable protruding from the clutch case cover. The MT07 push lever is slightly longer and so affords greater leverage, and thus lightens the clutch action.

Clutch push levers
Push levers comparison – Top: original FZ6; Botton: MT07

To remove the lever:

  1. Loosen the clutch cable to gain some free play; this can be done at the clutch lever (winding it all the way in) and half way along the cable (awkwardly tucked under left hand side of air box).
  2. Prise up the tab on the push lever and then slide out the clutch cable from it.
  3. Pop off the retaining circlip on top of the lever, then slide off the push lever with the spring beneath.

Do make sure your toolbox has a pair of ‘outer circlip pliers’ for this job, otherwise you’ll just be setting yourself up for frustration and probably end up scratching paint on the clutch case…

Refitting the MT07 push lever is pretty much the reverse, but you need care in aligning the lever. Do also stick with the FZ6 spring, the MT07 one does not fit.

  1. First turn the push lever axle protruding from the case fully clockwise (it only has around 90° of play)
  2. Slide on the spring (it only fits one way up)
  3. Slide on the MT07 push lever, so that it is pointing towards back of bike. The original lever has a dot on it that lines up with a small arrow on clutch case, but not the MT07 lever doesn’t. Nonetheless, compare the two and you’ll see how to align it the same. You’ll need to manually push the spring back to slot the end of it over the lever.
  4. Slide on the washer and then the affix the circlip.
  5. Attach the clutch cable and adjust slack (lever free play should be 10-15mm)
MT07 Push lever
MT07 clutch push lever fitted on FZ6

If you finish with almost no resistance at the clutch lever and it not springing back, then your lower push lever is not aligned correctly. When aligned, you will not be able to turn the lower push lever any further clockwise by hand, but when the cable is attached you will via the clutch lever. The biggest faff is lifting the tank and removing the air box to access the clutch cable adjusters hidden underneath it…

Did it work? Yes, it certainly lightened the clutch quite noticeably, making riding a lot more relaxed. The clutch bite position is still quite far out (when keeping free play in spec), with only slight difference in that regard. Some have warned of cable rubbing due to different angle, but I’ve not encountered any issues in this regard. Either way, definitely a mod worth doing and not too much costly.

The part you need is: 1WS-16340-00 (“PUSH LEVER ASSY”). Should set you back around £23-25 new, but you may find it cheaper second hand. Buy from Fowlers UK here.

References:

Full credit goes to this forum thread, which has more details and I definitely recommend reading too:

 

Author: Arthur

Seasoned London commuter, doing my best to stay rubber side down and never stop moving forward.

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