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kz750 clutch problem
- whirlwind598
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I was attempting to adjust the clutch pushrod from the access cover on the left casing.
After that I pulled the clutch lever and heard a pop. The lever wouldn't retract afterwards.
I completely pulled the right casing off as well as removed all the clutch plates. Bad idea I know :l put that side back together still need a new gasket unless any of those make a gasket sprays/tubes from AutoZone work?
Pulled off the left casing and removed clutch cable. Old one was very gummed up so I replaced it. Hooked it all back up and there is little resistance in the lever and clutch doesn't disengage so I can't shift gears unless the bike is on the stand.
Any ideas what I can look for to correct this? Or any more info needed?
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- 650ed
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It sounds like you do not have the manual for the bike. If this is true, you are begging for trouble pulling things apart and trying to put them back together without the manual; that is a very bad idea.
I suggest you stop at this point before you create bigger problems for yourself. Buy a manual, then undo whatever damage you may have caused. The Kawasaki Service Manuals are usually available on eBay. Be sure to get the one for your exact model/year bike.
No one has EVER regretted buying the manual. It is worth its weight in gold. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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- whirlwind598
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- martin_csr
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When installing the new cable, did you inspect & check the operation of the clutch release mechanism? And you're sure the clutch end of the cable is properly seated?
When doing the clutch adjustment, on some models, you're supposed to turn it counterclockwise first until hard to turn, then clockwise 1/4 or 1/2 turn.
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- whirlwind598
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The old cable was whole but the sleeve on the lower end was so packed with dirt and grease I could barely move it with some pliers.
I put the new cable exactly how the old cable sat. And cleaned and greased the operating arm and bearings. The spring may be wearing down but I know that isnt the main issue. I have a feeling it has something to do with the pushrod but I dont know enough to find out. And the manuals dont explain how the clutch actually operates haha
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- 650ed
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whirlwind598 wrote: ...............And the manuals don't explain how the clutch actually operates haha
Am I correct in assuming you are using some crappy Clymer, Haynes, or other aftermarket manuals? I ask because Kawasaki Service Manuals have VERY detailed descriptions in the MAINTENANCE - ENGINE section on exactly how the clutch operates. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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- martin_csr
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Some guys don't realize the owner's manual is kinda hidden in a pull-down document case on the underside of the seat.
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- whirlwind598
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- martin_csr
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The pop. My guess is if the clutch adjustment doesn't do anything, then you'll need to figure out what popped. If the old cable didn't break & the new cable is correctly installed, then the next thing to check would be the clutch release mechanism. Can you tell if it's operating correctly?
Note: there are 2 types of mechanisms for the 750H --- you'll have to compare yours to the diagrams to figure out which one you have. My 81 650-CSR has the spiral ramps & when fiddling w it, you can see how it operates.
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- whirlwind598
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- whirlwind598
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