Clutch help needed

Ok, i just switched motors, and am having what I think are clutch adjustment issues. When ever I take the bike out, the clutch cable feels like it breaks, but doesn't. It seems like the piece at the end of the cable, motor end, is popping out. When I tear back in to it, read the manual, and set it as it states, it still happens. I'm assuming its an adjustment issue but can't seem to dial it in. If any one can give me some suggestions about where to start from, settings on the adjusters and the adjusting screw it would be helpful. Its a 93 kz 1000p.

Post edited by: Sweet Back, at: 2006/05/24 20:24

All good now. Just had to pull it all apart, start from the beginning.

Ok...here's what You do...pull it all apart and start from the beginning...

:silly:

Sandy...with Super Mechanics like you, that is why we get on here to find answers to our problems. Such insight, such great mechanical knowledge, such wisdom in the workings of internal combustion engines. I'm so glad we have such smart guys like you here to help us in our time of need. Give yourself a big pat on the back!!! LOL

Sandy...how do you like those .410 cams? Are they touchy on the street? Peaky? Thinking about putting in a set in mine but don't want anything that is "racy" for the street on this bike. Low end power loss? How does it pull from idle?

Hey Sweetback: Had the same thing (exactly) happen to me earlier this season when I was adjusting my clutch. Turned out the factory service manual from Kawasaki was wrong and my Kawasaki owner's manual was right. The FSM said to loosen the cable and lock nut at the adjustment screw. Then, turn the clutch adjustment screw clockwise till resistance and back off 1/2 turn then tighten locknut...wrong. OM said to turn adjustment screw counter-clockwise till resistance and back off 1/4 turn...right!
On the upside, I learned what it takes to ride for several miles into town with a "broken" clutch cable. Intersections with red lights can be tricky!

Sandy, what can I say? You are dead on. So...insightful. LOL

Basically just made everything completely loose. All adjusters, and bolts and screws and cables. Apparently I had made my mind loose before attempting this. I love how the mechanic at the local dealership was sure it was a bad clutch. Had me lookin at the manual to see what was involved. Can't blame him, he didn't see it. But still, you gotta wonder.