clutch wont engage

hello, I have a 78 kz1000 that i am trying to get back into running condition. I just put a new clutch cable on it and now the clutch wont engage. it goes from 1st to neutral without pulling in clutch...when i am in 1st i try and pull in the clutch to get it rolling but it locks up..this is how i realized the clutch was not engaging...can anyone help?

did you hit it with a hammer?

joking aside behind the left hand cover is a clutch actuator this can be adjusted if you havn't done this there is your problem.

on my bike there was a small rectangular inspection cover that is easily removed to do this hope this helps.



[/quote]

As Kano said. plus: With the clutch cover off, pull out the long push rod that the actuator contacts. Clean it real good, and roll it on a flat surface. There should be no warp/wobble, then grease it up and put it back in. Make sure the actuator fits over the rod properly, and that the cover fits flat over the entire mating surface. Don't over torque the screws.

Adjust the clutch screw on the outside of the cover (in rectangular area) by loosening nut, then turning scre gently in until it contacts, then loosen 1/16 off, tighten nut back down.

Good luck friend, let us know...



PS> HAHA Nice pics Kano.

i already did this, but i will give it another shot and see what happens.

just trying to help!

should it be in neutral or 1st or does it matter

shouldn't matter for clutch adjustment.

ok i just adjusted it again...i now seems like it is disengaging but not all the way...do i need to tighten or loosen the adjustment screw more...as you can probably tell i dont know too much about bikes.. slowly but surely trying to learn...thanks for the help

ps. i have always loved motorcycles but my parents never let me near them...now that i am on my own i am trying to learn more. i picked up this 78 kz100 for a grand and am really interested in learning how to work on these guys..what advice do you all have for a beginner...any books, videos....just learn by doing...?

I was in the same boat as you 3 years ago. I found that a Factory Service Manual, KZrider forum, and hands on time with the bike all helped to figure most of this stuff out. Often once you do it the first time, it is easy to reproduce.

It will take some time to become really well aquainted with your machine, but soon you will know when something doesnt sound right and be able to identify what it is.

For general knowledge:
- oil and filter changes
- plug reading (condition of the plugs)
- points and timing adjustment
- cable adjustments
- electrical troubleshooting

Are all skills that you will eventually need to do, but you can always turn to KZrider for assistance.

After that ....valve adjustments, carb rebuilds ect... will follow.

Be sure to clean and lube up your chain on a regular basis and change your oil within a reasonable timeframe.

I was a completed "NOOB" and now I buy basket cases and flip them for fun. These bikes are great to work on.

Have fun.

Pull the clutch pusher out (under the clutch cover ) and make sure the little ball didn't bore a divot into the end.You'll have to take the clutch out to get at it.If the ball made a deep impression no amount of adjusting the rod will help,you'll need a new pusher..

sometimes if you run them really hard and pull in the clutch and hold it there while your slowing down they will weld the pushrod , ball bearing and clutch pusher all together but i've only seen that racing never on the street that is one of the main reasons outfits like ape builds clutch pushers with a torrington bearing set-up on them. it seems to disapate the heat better then the stock pusher.

Listed at Z1E:

www.z1enterprises.com/detail.aspx?ID=257

Good Luck!