clutch problem

Hi All,

Still having some clutch problems, sigh.

I just tore the whole right side of the bike apart to replace a messed up shift drum pin plate. Now, here's whats weird... bike starts up just fine in neutral. But, I can downshift into 1st gear without having to depress the clutch lever. Its like there's permanent tension on the line. I have tried adjusting the clutch adjustment screw, but no luck. Any idea?S I'd really like to ride tonight....:dry:

Forgot to mention...if I remove the whole cover chain so that there is zero pressure on the rod going to the clutch, it still acts as if there is pressure. perhaps I re-assembled something wrong on the other end? I really would hate to dissassemble that side again since Ive doen it about 20 times and just filled it with oil, but whatever y'all recommend, I'll try. There's plenty of play in the clutch plates incidentally, as I just reassembled them and checked.

-Dave:dry:

Post edited by: davidnard, at: 2006/05/29 15:15

how sure are you that its even going into gear??...i hate to tell you, but it sounds like your going to have to tear it apart again.....go to www.kz400.com and see if you can get a parts diagram, to make sure your putting it together properly....

Fairly certain; it makes that normal "pop" noise when you downshift into first, which it always did before. Prety sure its all back together same order also; printed out the parts diagrams and kept notes on the order Ipulled stuff off.

How much play should the clutch basket have? Maybe I didn't tight those 4 bolts enough?

-Dave

(riding the mountain bike for the day, sniffle)

there should be no play unless you pull the lever