Yamaha FZ6 Clutch Cable Replacement - How to

In this video I will be showing you how to change a clutch cable on a 2007 Yamaha FZ6. This job was a little more involved than I thought it would be since I chose to take out the battery box to create more space to finesse the clutch cable through the front of the bike. Generally, after reading about other FZ6 owner's experiences along with my own I would recommend changing the clutch cable every 40k km's to be on the safe side. Some cables last 25k km's some like mine last 65k km's. I just wouldn't want to be stranded again, being forced to clutchless shift.
Specs:
Clutch cover perimeter bolts for bracket: 8.7 ft-lbs
Clutch lever free play spec measured at end of lever is: 10-15mm
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[@svaz2006]

Wanted to say 'thank you!' for the vid. It took my about 2 hrs to replace the cable - not bad for something I'd never done before. I also removed the airbox & battery, to make things easier, although I did not have to remove the tank or unscrew the cable bracket. One piece of advice for others is not to forget the hose on the back of the airbox when putting it back in!

[@Calvinm]

Happy to help! Glad you got your new cable in without much drama 👍 happy riding

[@77TickTockTime]

Good vid, definitely a pain in the rear to do this work. Not sure if it's much better than pulling the airbox and battery box but I cut my old cable in half near the bend and then used some duct tape to pull the cable into place in each direction (from the middle of the bike). For routing the front near the airbox, I used a handful of zipties and long needle nose pliers to help guide and pull it into place.

[@thomasrelf6118]

Cheers for the video, I changed the cable out pretty quickly after watching your guidance. Unfortunately the return spring doesn’t want to pull the lever back so need to replace that now.

[@Calvinm]

Glad it helped!

[@djlancer88]

My next project, got a new clutch lever CRG shorty I have to put on too. When I did my plugs I noticed the adjustment underneath looked almost maxed out. Thanks for the video

[@Bigburt-]

Did this without removing whole airbox, just undoing gas tank front screws, and yeah worked fine, clutch is way better now

[@leadnitro3]

Have you heard of the mt07 clutch arm mod? Its apparently a direct fit and supposed to help lighten the clutch lever pull on the fz6, might want to do it on mine someday. Great videos btw!

[@Calvinm]

I have heard about this! I might have to give it a shot 👍 Thank you, glad you enjoy the videos!

[@chriswilliams33]

@@Calvinm I've done the Mt07 clutch mod much easier to pull the clutch. Listed as Yamaha clutch lever assembly BU03-E6340-00 bought the assembly off eBay. Should be around £20 or $25. Easy installation & although the lever is around 1.5 cms longer it only slightly changes the angle of operation, no rubbing of the wire occurs.

[@thanosferrarichanel]

@@Calvinm I have also done the Mt 07 pull lever mod on my s1, and I have to say, it makes the clutch so much lighter. It makes life easier going through traffic and it even has a bit of a longer grab point so low speed manouvers are a lot easier too.

[@igoldin74]

@@thanosferrarichanel could you please point out to the DIY tutorial for that?

[@Bigburt-]

@@Calvinm Did you ever do it? I did it to mine as well and tbh I cant really tell the difference.

[@ModernJargonFailure]

great video, do you ever upgrade to the FZ1 or can u verify any similarities or differences in same operation? HTis vid helped me to accept i must pay a mechanic to do this at least the first time to avoid risking destruction of my new cable due to being dummy ont he slack issue

[@simonsutherland15]

It's easier to change the clutch plates than the clutch cable, Yamaha what were you thinking? also why are the gross the adjuster nuts half way up under the airbox, instead of the other end where you can reach it? this bike baffles me!

[@huiputka1]

Absolutely mind boggling. Had tens of bikes, worst design ever

[@winterband1]

How did you store the gas tank while working, did it continue to drip gas? My FZ8 clutch cable has finally snapped at 52,000 miles (83,000 km) so I'm due for this job.

[@Calvinm]

I found that the gas tank didn’t drip out the fuel spout when left on the ground. Didn’t seem to matter if the gas tank was full or nearly empty.

[@이창윤-x7f]

I'm enjoying it. I have a question. Have you ever replaced a front sprocket seal? There's a leak in that area. If I replace it, is it easy to work on it?

[@Calvinm]

I have not had to replace the front sprocket seal. It might be challenging to pull because of it's size. A seal puller would certainly help get it out. Or try threading a wood screw into the seal then yank it out. Be careful around the output shaft and seal housing though!

[@이창윤-x7f]

Thank you so much. The repair shop said we had to break down the engine, so I was worried. It's simpler than I thought. Thank you so much.

[@SPRINCLES6]

just realized you made this video a couple of days before mine popped

[@Calvinm]

Dam! Best of luck with the replacement!

[@MetallicaSindre]

Did you have to loosen something underneath the air box before pulling it off? I'm thinking of the area just over the throttle bodies.

[@Calvinm]

Yes, there is an allen head bolt that clamps the air box to the top of the throttle bodies. I thin it's a 3mm allen. It's a tight space.

[@finikwa877]

Way more work than needed

[@andrei9402]

Hi, does the clutch cable have to be a certain thickness? I found one 115mm thick and I don't have a caliper to measure the one that just broke 😅

[@Edmondsonracing]

Do you happen to have the part number for a OEM clutch cable for the 04 fz6? S1 I believe

[@Calvinm]

The OEM part number is: 5VX-26335-00-00 I find all my part numbers on partsfish.com link: www.partsfish.com/oemparts/a/yam/50045b97f8700209bc794164/steering-handle-cable

[@michaelmeade1844]

Oooooooooooh the video finally dropped!

[@Calvinm]

Another one to come soon about this painful experience haha.

[@lhanders1]

Hmm... Might be I should prepare for a replacement of my clutch cable.. Newer replaced and ODO says 90k km..

[@Calvinm]

Ya, that cable could pop any minute now 😂

[@cesarrodriguez2493]

how long did it take you?

[@Calvinm]

Around two hours while filming.

[@jamalmontgomery5849]

What size is the cable

[@TOMYL27]

Thanks !! 😊

[@hunterman600cc]

What about 70k miles?

[@Calvinm]

That’s a lot of mileage for one cable. Congrats on having one cable make it that far!

[@JohnRivera-c7w]

Wow such a royal pain in the butt to have to replace one cable, just got mine and I have to change it :(

[@h4xi0rek]

Changing cables is possibly one of the most annoying jobs on this bike, especially on the throttle side.

[@Calvinm]

FACTS!

[@h4xi0rek]

@@Calvinm and my clutch cable snapped today :/. Fortunately, just about 1km away from the hotel, though more than 300km from home. No warning sides and it snapped in the place that I kept lubricated quite often (near the clutch lever, just at the start of the housing bend).

[@h4xi0rek]

Update - I managed to find a replacement cable quickly and replaced it at the hotel parking space :D. The clutch lever needs waay less pressure now to be disengaged. Also - the Teflon coating of the old cable, covered by the metal bend was completely torn apart. Anyways, I returned home with no issues down the road fortunately :)

[@know1n359]

LEAVE HER ALONE!!!!!!

[@ModernJargonFailure]

???what???