Clutch Release Mechanism

  • grumpy56
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Clutch Release Mechanism

09 Oct 2011 07:47 - 09 Oct 2011 07:49
#482124
The "J" has been running great for quite a while now, until yesterday. Was about a mile from home and went to shift into third (I think) and clutch lever to the grip. Thought I broke the cable. Funny thing though was the engine was not in gear. All neutrals no matter the position of the shift lever. Anyway, got a tow home and pulled the cover and the cable is fine. What I'm thinking is perhaps my clutch release doohickey is shot. Not at home this week so can't fool with it. Driving me CRAZY. Anyway, back to the problem...My shop manual does not depict the cam assembly I have. However, in looking at the parts book, it seems like they changed the entire mechanism in 1982 and is the one all the later Police bikes use. Anyway, once I rotated it back to what I think is the correct orientation and put the cover back on, I had full clutch at the lever, for a second anyhow, then POP. Lever to the grip. Also, when I pull off the whole gizmo I do have first gear and neutral (which makes me happy). Anyway, was thinking that perhaps the ball bearings have worn and are not engaging. Does that sound reasonable to you or do you think I have other issues? Also, anyone know a good source for all the parts in there? Called a Kawasaki dealer yesterday and they were of absolutely NO HELP. I wonder how some of these clowns stay in business. Oops, many haven't eh? Info appreciated. Thanks.
Lewis
1982 KZ1000-J2
2006 HD FXD35
1970 Suzuki T350
1972 Suzuki GT380 (In-Process)
In The Past...71 TM400, 72 H-D SS350, 72 GT380, 75 Z1B, 77 XLH, 79 CB750K
Last edit: 09 Oct 2011 07:49 by grumpy56. Reason: word

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  • Motor Head
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Re: Clutch Release Mechanism

09 Oct 2011 09:35
#482134
Worn Ball Bearings is possible, do they look out of round?
I'm wondering if the adjustment is off. Between the cable and the release mechanism. Where it ends up going over on the ramp, to much travel at the ramp and cam.
Back off the cable for full slack, maybe even the barrel adjustment midway on the cable housing. Then see if the adjustment under the small 2 bolt cover can be adjusted after first putting the cover back on. Then readjust the cable. Your service manual should show this, if you need a copy, download the one in my signature.
1982 KZ1000LTD K2 Vance & Hines 4-1 ACCEL COILS Added Vetter fairing & Bags. FOX Racing rear Shocks, Braced Swing-arm, Fork Brace, Progressive Fork Springs RT Gold Emulators, APE Valve Springs, 1166 Big Bore kit, RS34's, GPZ cams.
1980 KZ550LTD C1 Stock SOLD Miss it
1979 MAZDA RX7 in the works, 13B...

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