Clutch issue/Checking Timing

Would also assure that:

Push rod isn't damaged, especially at the ends;

Ball bearing is present (hasn't been lost).

Good Fortune!

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i dont mean to be a dick here but.

when you had the side cover off (where the clutch plates are)
did you even think about working the clutch (lever at handlebars) while this side cover was OFF and see if your presure plate was moving in or out ?????

just trying to help here.

I tried testing with zero gap, but it did not work either. I also took the clutch cover off and when I pull the clutch in, the plate barely moves. I am starting to think that either the push rod is bad/bent, or the clutch cable is stretch too much.

When I took the clutch cover off, the ball bearing was still in. How do you get the push rod out ? From the left or right side ?

When I took the clutch cover off, the ball bearing was still in. How do you get the push rod out ? From the left or right side ?

It should come out on the left side with the sprocket cover removed. Give it a slight twist when removing it.

The sprocket cover is where it says "Kawasaki" on the left hand side where the alternator and starter motor are correct ?

Yes, that's the left side of the bike(as you sit on the seat). The cylinders are numbered left to right too.

Right after posting my last entry, I went back to the garage to check on getting to the push rod. I got the sprocket covers off and took the push rod out. It had so much old oil and grim cake on it that I am thinking that it was being stopped from pushing the clutches. I'll do the clutch adjustment tomorrow after work and see if it works correctly now. I'll let you know one way or the other tomorrow.

BIGKEVIN wrote:

When I took the clutch cover off, the ball bearing was still in. How do you get the push rod out ? From the left or right side ?

The ball bearing is what the push rod pushes against.
The ball bearing comes out only after the push rod comes out, on the left side of the bike.

Good Fortune!

I use paint thinner to degrease the clutch push rod on my bike. The location will get chain lube on it and with dirt can possible damage the push rod seal.

With the sprocket cover off, clean and inspect the throw out mechanism for the clutch push rod. Some wheel bearing grease(a small amount) is about all it needs now and then.

Look at the cable condition for signs of wearing/stretching too.

BIGKEVIN wrote:

...took the push rod out. It had so much old oil and grim cake on it that I am thinking that it was being stopped from pushing the clutches....

got the sprocket covers off and took the push rod out --- the ball bearing will come out the same hole that the push rod came out of.

Be sure the ball bearing isn't omitted when reassembling.

When reassembling, the ball bearing goes in first, before the push rod.

While the push rod and ball bearing are removed, it's okay to spray some WD40 into the hole where the push rod and ball bearing came out from. As this should help clean and remove all the old oil and thick gunge inside the push rod passageway.

As earlier noted, examine the push rod carefully to assure it isn't bent, and that the ends aren't damaged. Also assure the ball bearing is in good condition.

Good Fortune!