Clutch issues?

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18 Nov 2012 05:06 #558922 by Mr.Wizard
Clutch issues? was created by Mr.Wizard
Full disclosure: I have no idea what I'm talking about, so bear with me.

Recently bought a 440 and love it. I was driving on the interstate when I had a total loss of acceleration so I pulled over and did some experimenting. The engine idles and rev's fine, but there's only the slightest hint of power going to the wheels. I cracked the right side, cleaned everything up and replaced the very worn clutch plates, but still nothing.

The bike seems to be a hodge podge of KZ parts, so I'm not sure how accurate each manual I'm following is, but I noticed that my model didn't have the small sphere (bearing?) that should be inside the center of the clutch plate assembly, the rod that goes behind the bearing has a little play in it (Which seemed like how it's supposed to work?). The gears all seem to be shifting fine, I just can't get enough power to actually move.

Theres a slight clacking when I rev it and let the clutch past the friction zone, but I haven't given it much because I'm worried I'll make whatevers wrong worse.

Any ideas? Do I have a ground down something or another in my transmission? Please help, I'm dying without my bike!

UPDATE:



Did more research, the engine is the same style as the "1982 KZ440D3 LATE MODEL" with the clutch cable connecting on the right side. It has a double sided spring plate pusher and doesn't use the spherical ball or have a clutch push rod assembly from the left side of the bike. I opened her back up and everything looks like it's assembled correctly based on that manual. I pulled out the clutch arm that the cable attaches to and shined a light into the hole facing down, I can see the end of the spring rod pusher clearly, it looks and feel like it's engaging fine.

What the hell gives?

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18 Nov 2012 07:00 - 18 Nov 2012 07:01 #558926 by Patton
Replied by Patton on topic Clutch issues?

1973 Z1
KZ900 LTD
Last edit: 18 Nov 2012 07:01 by Patton.

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18 Nov 2012 12:54 #558953 by Mr.Wizard
Replied by Mr.Wizard on topic Clutch issues?
Already posted the same exact thread there :-). Ive scoured the appropriate engine manual to no avail

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18 Nov 2012 16:13 #558984 by Mr.Wizard
Replied by Mr.Wizard on topic Clutch issues?
Figured it out, stripped to hell front pulley. Looks like it was machined smooth, not a single tooth left.

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18 Nov 2012 16:38 #558989 by wireman
Replied by wireman on topic Clutch issues?
Belt drive pulley?
If it chewed up a pulley Id say the belt and other pulley arent long for world. B)

posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.

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19 Nov 2012 11:47 - 19 Nov 2012 11:48 #559118 by wireman
Replied by wireman on topic Clutch issues?

Attachment Image.gif not found

Cant seem to find a front pulley part number
B)

posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.
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Last edit: 19 Nov 2012 11:48 by wireman.

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