Kz 400 clutch release lever bad??

The clutch on my kz 400 is extremelly hard to pull in, and the release lever under the sprocket cover sticks and dosent move freely. I have lubed it to no end and it still dosent move freely. Is the release lever the same on the 650, 900, and 400 the same one? It looks like it is but i dunno.

Just went on kawasaki.com and here are the bikes that use the same part.


Please wait ...





Model (22):
KZ1000-A1 (KZ1000) (1977)
KZ1000-A2 (KZ1000) (1978)
KZ1000-A2A (KZ1000) (1978)
KZ1000-B1 (KZ1000 LTD) (1977)
KZ1000-B2 (KZ1000 LTD) (1978)
KZ1000-C1 (Police 1000) (1978)
KZ1000-C1A (Police 1000) (1978)
KZ400 (1974)
KZ400-A1 (1977)
KZ400-A2 (1978)
KZ400-D (1975)
KZ400-D3 (1976)
KZ400-D4 (1977)
KZ400-S (Special) (1975)
KZ400-S2 (Special) (1976)
KZ400-S3 (Special) (1977)
KZ900-A4 (1976)
KZ900-A5 (1977)
KZ900-B1 (LTD) (1976)
Z1 (Z1) (1973)
Z1-A (Z1) (1974)
Z1-B (Z1) (1975)

Does anybody have one from a bike thats in the list that they wanna sell? Let me know

try taking it apart and cleaning really good then lubing it up,could just be old gunky grease;)

I have did that 3 times today and it didnt get better anytime after i did it.

On my 82 GPZ1100 B2 under the sprocket cover is the clutch release mechanism. Over a period of years the pivot worn where the clutch cable attached the the rest of the actuation system.

I drilled out the pivot rivet and used a high strength bolt as a pivot and have used it for several years with no problem. I think the bolt is 1/4" in diameter. I lube it when I do work under the cover and it's working well.

does your bike use the pushrod to actaute clutch?
if its dry, could be a contributor?....just taking a whack at helping!.......keith

oldkaws4ever wrote:

The clutch on my kz 400 is extremelly hard to pull in, and the release lever under the sprocket cover sticks and dosent move freely. I have lubed it to no end and it still dosent move freely....

Am uncertain about which parts are sticking and not moving freely.

Perhaps this diagram could be used as a reference.

[Click on diagram for larger view]

#6 slides into #4, and #4 goes in but gets stuck when it bottoms out.......if that makes any since. Plummen is sending me one of his, so i will let you all know if that was the problem, when it gets here and i get it on. Thanks