Clutch Adjustment Woes

I just got a new chain cover and now my clutch won't adjust properly. I adjusted it as per the manual, and even with the center adjuster fully expanded as well as the clutch lever adjuster, there is still so much play that the clutch can not disengage.

Before I tried adjusting it, the lever was very stiff and would not disengage the clutch fully, hence why I went to adjust it.

Please disregard this post. See kzrider.com/forum/2-engine/589006-chain-cover-trouble instead.

I had the same problem with my bike. It was a while back but I cant really remember what I did. When you say chain cover, do you mean sprocket cover? The one with the clutch adjuster? if so make sure that it is flush and not angled at all or the mechanism that pushes the clutch in won't push at a straight angle, then adjust the cable for slack, not the clutch. That mechanism the pushes the clutch out is for fine tuning. After you adjust for more slack with the adjuster on the cable then use the clutch mechanism. As for that super stiff feeling you had before, I had that after mine sat for a while after I broke my clutch wire and I installed a new one. I just pulled in the clutch lever and popped it into first. It seemed to break loose the clutch plates and work just fine. You might want another opinion on this method though

I tried putting it into gear, just with the bike on the center stand. It shifted, very roughly, but it shifted. But it didn't fix anything. I was able to ride it around the block, but it was sketchy because my left wrist felt like it was about to fall off and stopping, even with the clutch pulled in, killed it.

Thats weird, I've only ever worked on mine so Im not sure about the gpz and if its the same kind and screw type mechanism. I saw on the other post you did adjust the cable and still too much slack. is it a new cable? it could be breaking down inside the casing and stretching and breaking every time you pull it in. This happened to me also.

What manual are you referencing? Do you have the owner's manual? Which way are you turning the clutch release adjusting screw? Clockwise first, then counterclockwise? Or vice versa, counterclockwise first?

kz.bike-night.com/manual.html

I do not have the owner's manual. I'm turning the adjusting screw clockwise (in), then slightly counterclockwise (out), just like the manual says. I did try it the other way, just to see if it changed anything though. It didn't.