Replaced Clutch Plates: No Tension on Clutch Lever

Yeah - that's the second time I've heard this. I suppose it's possible that it did come out somewhere along the way. Assuming that I can't find it in my messy garage, what size is this ball (bearing)?

Found a thread concerning the ball for a KZ1000 and it said a 3/8" - does that sound right?

raulfd4 wrote: ... 3/8" - does that sound right?

YES.
And supposedly also available as an active part at Kawasaki dealers.
21 600A1200 BALL STEEL 3/8' 1

See kawasaki.com diagram and parts info.

Lots of good info on kawasaki.com, including parts diagrams, part names, part numbers, models sharing same part, availability, etc. Here's a link for help with navigating the site and finding information.
kzrider.com/index.php?option=com_kunena&...w&catid=13&id=376734

Good Fortune!

The clutch disks that you replaced, are they stock units or aftermarket with additional plates. I have read a post on another site where the poster had installed a new clutch, but the new aftermarket one came with additional disks and the poster did not install them thinking he should only put back as many as he took out. The clutch kit required the additional disks and once he installed them the issue was solved.

Same amount of plates installed and included in new clutch as were removed.

Thanks Patton. That's a helpful thread.

So, I took the cover off of the left side of the bike, where the clutch adjustment screw is. I took out the pushrod and used a telescoping magnet to reach into the hole and see if the ball bearing was there. It wasn't.

Is that where it should be? Or do I have to access it from the right side of the bike, where the clutch basket, etc. are?

It should come out from either side, if I recall. EDIT: I recall incorrectly. It should only come out on clutch side.

Another ball bearing removal theory :lol:

With pushrod removed, clean out the passageway as much as possible to clear any accumulated gunge that would make it more difficult for the bearing to roll out of the passageway.

Then, with bike leaning toward its left side, spray WD40 liberally into the passageway hoping to flush the bearing out. Watch carefully in case it hits the floor and rolls.

I haven't tried this, and it may be a stupid idea. :laugh:

Good Fortune!

Actually, in the process of using the magnet to try and extract the ball, a fair amount of grunge did come out. However, there still was no ball attached to the magnet - and it was definitely hitting up against whatever part is at the end of the cylinder the pushrod goes into.

Either way, your response would lead me to conclude that yes, the ball should be found at the end of the long pushrod after it is removed from the left side of the bike. And... it's not there. So I need to get one and replace it.

That being said, once I get the ball replaced and close everything up again, the adjustment screw should then have enough tension working against it for me to adjust the clutch cable, right?

It should, if nothing else is missing. I'd go to www.kawasaki.com and look at the diagram of your clutch mechanism, comparing what you've got, with what the website shows.

Alright folks, it's been nearly a month now, and as a weekend warrior with this bike, I'm starting to reach my wit's end.

I've uploaded a video on YouTube that explains everything up to this point and IT IS STILL NOT WORKING :pinch:

Please stick with all 12 minutes of it and help me out here. This shouldn't be this hard! :dry:

Here is a link to the video: link


My main concerns are:

1) The issues with the adjuster at the clutch lever.
2) The mid-cable adjuster
3) Potential mis-information in Clymer manual diagrams (1974-1878 vs 1979-1983 model diagrams) of the pressure plate
4) The 3/8 in. steel ball (If it's missing, why, when I replace it, does it not go back together right?)

The ball bearing goes into the push rod tunnel just before inserting the pushrod. All done on the left hand (gear shift) side of the bike.

The ball bearing isn't part of the clutch basket assembly.

The ball bearing is located between the inner end of the push rod and the plain end of the pusher.

After pulling out the push rod, the ball bearing comes out the same hole. But the pusher doesn't come out the hole where the push rod and the ball bearing came out.

If looking inside the hole after removing the push rod and the ball bearing, might be able to see the plain end of the pusher.

Good Fortune!

Edit: Above is applicable to large Kaw fours.