Kz900 Engine casing crack after slight explosion. No clutch activity now.

Actually you're all wrong. My MKll did this exact same thing to me last year.The pushrod welded itself to the ball & stock pusher behind the clutch. When everything seized up it blew the worm gear out the left end and broke the outside cover.

The fix is the APE clutch pusher with the needle bearings
( I thought this bike had one...lol) a new pushrod and worm gear adjuster and a cover. Make sure you hone the pushrod hole or you may find burrs and scrapes that will prevent the pushrod from moving properly. I did.

I've got a Z1 clutch cover you can have for the cost of shipping.Everything else you can get from Z1 Ent. PM me if you want the cover..

Jack, I don't think you are right. His additional pics showed no damage to the pusher gizmo. Hard to tell if the 5mm flat head set screw is still in the middle for adjustments but what broke the cover was the lack of bolts. When he pulled the clutch, the cover was flexing and I suspect that the clutch was stiff from lack of lube and it just snapped the cover when the clutch cable was pulled in. The pusher and rod put pressure on the cover and with only a couple bolts, the flexing broke the cover I think. I have loosely installed the countershaft cover myself in the past to test clutch pull and adjustment feel and noted that it flexed the cover if the cover wasn't solidly bolted in place. I

Jack, I don't think you are right. His additional pics showed no damage to the pusher gizmo. Hard to tell if the 5mm flat head set screw is still in the middle for adjustments but what broke the cover was the lack of bolts. When he pulled the clutch, the cover was flexing and I suspect that the clutch was stiff from lack of lube and it just snapped the cover when the clutch cable was pulled in. The pusher and rod put pressure on the cover and with only a couple bolts, the flexing broke the cover I think. I have loosely installed the countershaft cover myself in the past to test clutch pull and adjustment feel and noted that it flexed the cover if the cover wasn't solidly bolted in place. I would guess the fella who started this thread would be a happier rider if he bought a shop manual and did some basic maintenance and went through the bike before riding much more. Check for missing/broken case bolts, change fluids, clean/lube chain, check fasteners and TUNE UP the bike per the manual.

why is there no clutch adjuster screw in the end of the adjuster?

This is like watching a long lost episode of CSI!!!

I think I perceive some reticular hemorrhaging leading me to believe the clutch cover was straining to stay in place. But the end was unavoidable due to mounting points being under utilized. The end came suddenly and violently. The first fracture of the cover proceeded laterally and a fraction of a second later a second (COD) fracture made the two remaining fastening points non functioning.

But....the missing Camular Fastner!!! You cannot rule out foul play!!! :ohmy: :ohmy:

Better not be a 2 parter!!! :silly:

Jack wrote:

Actually you're all wrong.

I'm willing to bet you'll regret saying that

Take another look at the pics.


As to:

why is there no clutch adjuster screw in the end of the adjuster?

He's not familiar with the workings of the bike, so my guess is he removed it while attempting to remove the cover.

I'm still astounded by the "Actually, you're all wrong" statement, even "I" have never had the intestinal fortitude to say something like that.

steell wrote:

cmmman wrote:

That finned cover is sweet.

Is, or "was"

Haahaaa:laugh:

the finned part looks to be intact, faired better than the rest of it. I think i might need to make a mini finned cover for my 650 clutch adjustment screw.

Im interested to see how this turns out.

steell wrote:

Jack wrote:

Actually you're all wrong.

I'm willing to bet you'll regret saying that

Take another look at the pics.


As to:

why is there no clutch adjuster screw in the end of the adjuster?

He's not familiar with the workings of the bike, so my guess is he removed it while attempting to remove the cover.

I'm still astounded by the "Actually, you're all wrong" statement, even "I" have never had the intestinal fortitude to say something like that.

Please allow me to apologize for a poor choice of words,it's funny how things on the screen don't necessarily come across as intended....

The adjuster screw is gone because it got blown out when the pushrod backed out and broke the sidecover. Mine did exactly the same thing, all that was left was the "casing".

I think the Butler did it, he was having an affair with the upstairs maid in the basement, and was caught by the hidden camera in the corner placed there by the cook...lol

after looking at the pics I think a good inspection of all the parts is needed..

For reference:

KZ900 clutch from kawasaki.com

(shows the pushrod and ball bearing and earlier screw-type adjuster)

[click on image to enlarge view]

For reference:

79-80 KZ1000 Mark II clutch from kawasaki.com

(shows the pushrod and ball bearing and later screw-type adjuster)

[click on image to enlarge view]

Regardless of the different type pushrod screw adjusters,
am not understanding what forces are at play to propel a seized pushrod toward the screw adjuster.

And what is that piece with the blue stripe? :S

[click on image to enlarge view]