Shifter?clutch? problem

I repacked the clutch last summer and all is well there. However, prior to and after the repack I have been experiencing these issues: Start bike up, let it warm, pull in clutch, drop it into 1st and I get a BIG LURCH which occaisionaly stalls the bike. I've had this problem get progressively worse over the last two years.

When I start the bike, let it warm, shut it off, pull clutch and drop trans into 1st then back up to neutral, restart bike....I can then drop it into 1st with MUCH less of a jump/twitch/jerk whatever in the driveline. It's like I'm taking up some slack somewhere when I do this.

Also, this last fall I noticed that shifting through the gears has gotten less precise. The shifter now feels a little loose/sloppy, particulary in the lower gears.

Anyone have these symtoms before and what was your cure? My clutch MAY not be properly/perfectly adjusted although I dought it. I will rule nothing out and I'm all ears as to suggestions on what to check. Thanks.

On mine.
On the left side cove for the clutch is a small cover where the clutch adjust is. This adjustment changes how the pushrod opens and closes the friction plate. It seems that the rod is not pushing the plate completely free of the clutch. That is where I would start.

Does it only do this the first time you shift from neutral to 1st? If so, try this: before you start the bike put it in 1st gear, pull in the clutch, and rock it or push down on the kicker. If your clutch plates are sticking after sitting for an extended period of time (hours) this should break them free and eliminate the problem when you start the bike. Did you use Kawasaki clutch parts or aftermarket? I owned a BSA with a factory competition engine that had this problem because the friction plates would stick to the aluminum clutch plates after the bike sat overnight. I've never had the problem with my KZ650C1, but I only use Kawasaki parts. Ed

adjust your clutch at the lever and see if the lurching stops, otherwise try like flrcreations said.

Beware for that has happened to me. Your clutch cable is about to go out. mine did! No matter how much adjustment you make, it's not going to save you. I just had to make that sound so dramatic. Check your clutch cable, it can also be rusty.

Two summers ago I had a weekend of the lurches. Every time I put the bike into first it would lurch and usually stall. I adjusted the screw and locknut under the little left hand cover close on a dozen times over a Sunday afternoon and eventually got it right. Very frustrating.

JR wrote:

Two summers ago I had a weekend of the lurches. Every time I put the bike into first it would lurch and usually stall. I adjusted the screw and locknut under the little left hand cover close on a dozen times over a Sunday afternoon and eventually got it right. Very frustrating.

Thanks JR. Maybe I really don't have it all adjusted properly. I did pop a cable and put an old factory junker on temporarily, although I lubed the heck out of it. I'll get a new cable/lube up and try multiple adjustments. I'll crack that FSM and go by the numbers. Thanks all, I'll try the alternatives if the simplest fix doesn't work.

Lets hope it's something simple and you're spared opening the clutch basket.
Good luck

flrcreations wrote:

On mine.
On the left side cove for the clutch is a small cover where the clutch adjust is. This adjustment changes how the pushrod opens and closes the friction plate. It seems that the rod is not pushing the plate completely free of the clutch. That is where I would start.

same problem on mine: I ended up buying a new "bellcrank" piece or whatever you call the lever that twists the helix that pushes in the rod. BTW: make sure the lever is at a right angle to the cable in the area where it is trying to depress the clutch rod. That gives max leverage and maximum "depression" of the rod end.

650ed wrote:

Does it only do this the first time you shift from neutral to 1st? If so, try this: before you start the bike put it in 1st gear, pull in the clutch, and rock it or push down on the kicker. If your clutch plates are sticking after sitting for an extended period of time (hours) this should break them free and eliminate the problem when you start the bike.

I used to hold the clutch in and blip the throttle, wait a few seconds and blip the throttle.... do this maybe four times and it would free up the clutch. YMMV