Clutch pushrod case bushing.

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21 Jan 2010 09:32 - 21 Jan 2010 09:35 #343753 by coppertales
Clutch pushrod case bushing. was created by coppertales
The bushing where the clutch pushrod exits the case on my bike is worn causing a groove to be worn in the pushrod. This causes slop in the pushrod which will allow the pushrod to come out of the receptacle in the actuator. This causes the clutch to be mostly disengaged and I am unable to operate the clutch at all. Luckily, I have been able to limp home. I cannot find this part number on the KZ IPC. Anyone know what this part number is? I need to order one. I really don't want to pull the engine and split the case to fix this but there is no other option. Thanks....chris3

My bike is a 1982 KZ1100D1...

1982 KZ1100 A2
1982 1100 SPECTRE
1982 1100 SPECTRE
Last edit: 21 Jan 2010 09:35 by coppertales. Reason: add info

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21 Jan 2010 13:19 #343765 by 650ed
Replied by 650ed on topic Clutch pushrod case bushing.
As a temporary bandaid until you get a new bushing could you build up the diameter of the pushrod where it passes through the bushing using shrink tubing? Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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22 Jan 2010 07:43 #343913 by coppertales
Replied by coppertales on topic Clutch pushrod case bushing.
The pushrod is aluminum so that would be difficult. The bushing is steel which cuts into the pushrod. It will eventually break off. Seeing this bike is a shaft drive, it is a PITA to address this. I replaced the stock pushrod with a steel rod that was a bit longer to fit more securely in the actuator socket but for some reason, it came out again. I have a spare clutch basket and actuator so I will change out the whole system when I do it. I may just steal the bushing out of my KZ1100A2 and install the D1 engine in the A2 because that is my road bike and it is down for a base gasket(major oil leak)replacement. The D1 engine only has 20000 miles on it where the A2 engine has 50000 miles on it. Then I can overhaul the A2 engine at my leisure. It is nice to have two D1 bikes and one A2. I keep two of them licensed for the road and work on the other. Work on these old bikes never ends......chris3

1982 KZ1100 A2
1982 1100 SPECTRE
1982 1100 SPECTRE

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22 Jan 2010 13:54 #343967 by APE Jay
Replied by APE Jay on topic Clutch pushrod case bushing.
Are you talking about the clutch pushrod that goes thru the motor?

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25 Jan 2010 08:29 #344478 by coppertales
Replied by coppertales on topic Clutch pushrod case bushing.
No, I don't need the pushrod. I need the bushing that the pushrod rides in on the left side of the case between the clutch assy and the actuator that is connected to the clutch cable. Splitting the cases is the only way you can replace this bushing as it is flanged on both sides of the case so it stays in place. I will hit up the Kawasaki shop at lunch today. I need the ball too as it is toast. When the clutch pushrod jammed, it put too much pressure on the ball and it wore down....chris3

1982 KZ1100 A2
1982 1100 SPECTRE
1982 1100 SPECTRE

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