gpz550 clutch questions if you have a gpz550 read

my clutch was stuck the bike had been sat for ten years so you can imagine it was stuck so ive taken it all apart cleaned it ruffed up the friction plates an cleaned all the old gripe of the metal plates
gone to put it back together an noticed a ball bearing sat on the floor next to the clutch case that i removed and i was like "has that come from the bike" i worked on a few kwakers and never had a ball bearing it may not be from the bike but i wanted to just clarify that with some other people first before i put it back together if enything it could go on the center hole between the clutch shaft and the pin? maybe? let me know asap guys and i was wondering why someone hasnt uploaded a copy of the manual on here save us all some money just a thought

Here's a link to the GPz550 forum. You can download manuals there.

www.nwsca.com/gpz550/garage.htm

Be aware that the GPz clutch does not adjust the same way as all the other KZ clutches so please read the adjustment procedure before proceeding to adjust the clutch.

Good luck!

fallout3 wrote: my clutch was stuck the bike had been sat for ten years so you can imagine it was stuck so ive taken it all apart cleaned it ruffed up the friction plates an cleaned all the old gripe of the metal plates
gone to put it back together an noticed a ball bearing sat on the floor next to the clutch case that i removed and i was like "has that come from the bike" i worked on a few kwakers and never had a ball bearing it may not be from the bike but i wanted to just clarify that with some other people first before i put it back together if enything it could go on the center hole between the clutch shaft and the pin? maybe? let me know asap guys and i was wondering why someone hasnt uploaded a copy of the manual on here save us all some money just a thought

It would really help if you would add your bike's year & model to your signature line; these bike's have a lot of different parts.

If your GpZ550 is a 1981-1983 (that would be a KZ550-D1, KZ550-H1, or KZ550-H2) the ball bearing (if it is an individual steel ball) fell out of your clutch. It should be between the clutch push rod and the clutch spring plate pusher (see first picture) and will need to be installed of the clutch won't operate.

If your GpZ550 is a 1984-1986 (that would be a ZX550-A1, ZX550-A2, or ZX550-A3) that individual ball would not belong in there as Kawasaki replaced it with a ball bearing consisting of several balls and their races (see second picture). Ed

There are more manuals than you will know what to do with in my signature. Grab all of them in case they go away.

There are two types of KZ550 clutch actuators. They adjust opposite of each other. My signature has details for the ball-pocket type, which in on the 81 to 83 Gpz550's.



The push-rod's ball bearing can't come out on the sprocket side, but it can fall out on the clutch side. And as Ed said, it's only on the 81 to 83 Gpz550's.

lovely chubbly guys yeah so i mean it must be an 81-83 then i suppose but yeah ive put the clutch back together placed the ball bearing put the push rod in then the plate done up the 5 cluctch spring loaded 10mm bolt but now im having trouble with the other side i aline the ball bearings put the casing on an when i pull the lever its really tight and then the arm on the inside jumps if the ball bearings eny idea what to do from here?

You will need to open the clutch side up and put the ball back in. When you do, be sure to use a torque wrench and the torque specifications in the manual for tightening the bolts in those clutch springs. Too tight or too loose or not having all of them exactly the same will cause problems. Ed