Changed sprockets and now there is no clutch??

Try readjusting your clutch cable at all 3 points the way it shows in the manual first

where is the spring that pushes the pivot back with the cable end to completly release it?

Here the pic from the manual. Change the angle of the lever and there should be a spring.

Look at this, you can get the manual from member loudhvx, its in his signature for download.
home.comcast.net/~loudgpz/GPZweb/Mnls/Kz...ase99924_1018_06.pdf

Flyndrive wrote: Here the pic from the manual. Change the angle of the lever and there should be a spring.

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Thats one of the 3 adjustments on the clutch cable

ajp529 wrote: Yes I did happen to pull it out.

OK....he pulled the clutch fricken rod from the engine ?????

Arent we KZ guys told from birth not to do this ????

what happens when you pull the rod out....the ball bearing does what ????

so what is with adjustment of the cable stuff??? :dry: :dry: :dry: :dry: :dry:

I pull the pushrods out all the time and clean them up and reinstall the oppisite way, the seal will actually grind a groove in them if you dont clean the crud off once in a while.
Swapping ends on the pushrod keeps it from wearing in same spot all the time.

There are 3 differant clutch adjustments on the cable,that little cover in the center of sprocket cover comes off so you can adjust that actuator first,then the adjustment at the lever and finally the center adjustment on cable gets done.
You adjust the actuator differant directions on differant size bikes so check your manual to see which way it goes

Adjusting the clutch is important but I have to agree with 4yheKZ about the ball bearing that goes between the end of the clutch rod and the mushroom that pushes on the clutch outer plate. Without making sure that is in place means that all the adjusting in the world will make no difference at all.

Its a little tougher than people seem to think to get that ball bearing to fall out without being seen

I don't know about a 550 but my 900 push rod/ ball goes through the center of the transmission input shaft. The only place it could go would be out the hole that the push rod goes into, not inside the clutch or motor cases. The clutch actuator arm does look like it is too far forward as other members said. Moving that back a tooth will make the push rod travel futher.

On the 550's, the ball bearing can't fall out on the sprocket side. If he didn't open the clutch side, the bearing should still be in there.

I suspect the cable has come out of the sleeve at either the lever end or the actuator end. Or the cable came out of the holder at the actuator.

Also, if he adjusted the actuator according to the manual, the directions may be wrong for the ball-pocket type actuator.

In my signature, there is a diagram for the ball-pocket type with more detailed instructions on how to adjust it.
home.comcast.net/~loudgpz/GPZweb/ClutchReleaseMech.GIF

The ball is larger than the push rod, so cannot come out through push rod channel.

Hey,

Thanks guys youre awesome! It was the adjustment of the ball and ramp part of the clutch. Thanks!