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I had the same thing happen to my KZ1100. The disk that goes under the lever with the holes around it was all chewed up. I put one from the KZ1000 I rebuilt before I t parted it out and I haven't any problems yet.

fingers crossed.

I bought these rebuild kits for the carbs and used some parts of it.
Mainly the gaskets and the float parts, but had a laking like you 2 times.
Both times it was small pieces of rubbish from the tank that prevented the float needle to block the fuel.
Because I have an old petcock not much fuel leaked when it was closed but it poured out while running.
Cleaned the carbs and put inline fuel filters in and problem solved.
I don't like the vacuum ones because you have no control.

Eric

Been a while since I posted anything as Its been a while since Ive done anything with the bike. Today,I went down and rebuilt the fuel tap.Refitted it and put some fuel into the tank.So far so good.No leaks.The tap is holding and carb No.4 seems to also be holding,though I wont know for sure until after a couple of days.
I got the bike started. The weather is very warm today so it started up ok.Then I gave the throttle a blip and the whole thing died.Power out!!!
I checked the fuses and they all seemed good,scratched my head then went to check the battery. The battery was HOT!. Never had that before.The bike had run for ,maybe 1 minute maximum before I blipped the throttle.So,I reckon theres something very wrong there.
I pulled the battery out and fitted one from an old Honda I have lying around. It was a bit low and struggled to crank the engine over but it managed in the end and the bike started up. Blipped the throttle again.No problem. Revved it. Sounds good and happy.
So Ive now got the old (at least 10 years) Honda battery out and on charge. The new Motobatt (not even 6 months old) will be going back to the shop.
Thats it for now.

Ok,so swapping the cheap oil for better quality has not done anything noticable to improve the clutch action. Its still quite heavy at the lever and dosnt like to go into neutral.
As I posted before,I have been playing with the spacing of the hydraulic piston, but I cannot find a sweet spot.So,its time to open up the clutch and see whats going on inside.

No shrapnel,everything looking clean enough.

The pressure plates seem to be going in the wrong direction according to my Clymer. Anybody know how important this is?

2 steel plates beside each other?? That cant be right????

Some grooving on the basket.Not too deep but I want to get rid of it to be sure.
Problem now is,I dont have a 30mm socket or a clutch holding tool so I cant pull the basket of to work on it!!!!

So opinions on the direction of the grooves on the pressure plates and the 2 steel plates side by side? There are no pressure plates side by side and the stack starts and ends with a pressure plate (as the Clymer says).

the extra steel is common practice to help stiffen up an old clutch.
the frictions going that way i wouldn't worry about.all the ones i have seen had radial grooves.
a rag wrapped around the clutch basket and an air impact is usually sufficient to break the clutch nut loose.

hth,

leon

So,Leon,you dont think the extra steel plate would be the reason for the heaviness at the lever and the difficult neutral??

I like the idea of the rag and the impact driver but this time I went for the aluminium bar bolted onto the spring mounts


Its the only way to go if you want to snap off a couple of spring mounts!!!!!!!!!!!!!

Dayum, that bites.

well now you know why you won't be doing that again
tough lesson.

the extra plate would account for the heavy lever.
the trouble finding neutral is imho likely the pins and the claw that rotate the shift drum.or possibly the shifting dogs.

leon


p.s. take that extra plate and weld a handle onto it and voila clutch holding tool.

Just when you think you'r almost finished
Do you still have the hydraulic clutch?
Eric

So,I found a 2nd hand one from one of the boys at the Z1 OC GB. Should be on its way soon. I also ordered a new set of plates and a new set of springs,just to be sure. Well see what that does.

Congrats David.......
Not with the broken clutch but you just passed 30.000 views

Ha! Thats 30,000 people with nothing better to do than read about my incompetent spannering!!!
Talking of which,I got the clutch basket off today with a load of rags and an impact screwdriver thing.It worked a treat (Thanks Leon).
I had a go at filing down the grooves in the tabs on the basket;


Not sure how far to go with it. I dont want to take too much off.Any suggestions?
Nothing to do now except wait for all the ordered bits to arrive.