My friend has a 2008 zx6r with 40,000 Miles. The problem started when he had to keep adjusting the the clutch cable. It got to the point he had no play in the cable and the clutch wouldnt disengage so we took it apart to find the steels where blue, the fibers didnt look bad and mic within what the manual called for.

So we ordered a oem clutch fibers, steels, springs from the dealer.

We put them in to have the same problem. You cant get the clutch to disengage unless you keep turning it out but then you have no free play in cable. The manual says to have the arm at a 60 degree angle and its at 75 (this is at the case adjustment).

The dealer said the stack height is wrong so we mic it out and its dead on for the manual so then we mic a few other things such as the hub, basket, ect and its all within factory specs. They suggested trying to put a smaller steal in so we did that.

Now with a smaller steal just 1 swapped the lever at the case sits at 60 degree but again we dont have any free play. If we set it up how its suppose to the clutch wont disengage. Now if we keep tighting the cable the clutch will work some what but there will be no free play in the cable so something is wrong still.

The dealer said it must be a bearing or they dont know?

We swapped 1 2.6m steal for a 1.6m steal (dealer said to do)

We swapped clutch cables, Levers, Changed the oil, mic everything. All parts inside look better then my 04 636 with only 12k on it so we are at a total loss.

Yes the fibers where soaked in oil for 12hrs before install. We have took it apart 4 times and did step by step from the manual and still no luck.

Anyone have any idea what is wrong please help, Thanks