Clutch issue caused by me - need help

Hey guys,

I've been trying to complete the installation of new handlebars and in the process, my clutch cable split. So, I decided to replace the clutch cable as well.

Getting the old cable off was tough because I couldn't get the ball end off of the clevis down at the clutch release shaft. I actually ended up removing the clevis so that I could get to the cable end. In doing so, I believe I messed up some kind of preload on the shaft.

Now that I have the new cable attached at both ends, there is very little resistance in the clutch lever and the clutch doesn't disengage.

I've referred to manuals and it keeps mentioning a clutch adjustment screw but I can't find where that is on the bike. I have a shaft drive model and I'm thinking that the manual references chain drives specifically.

How do I get resistance back in the clutch lever and bring the clutch back to a disengaged state?

Anyone know where the clutch adjustment is on a KZ750 shaft drive? I don't have a manual for the shaft drive model.

No eBay APP ID and/or Cert ID defined in Kunena configurationI don't have that info, but here's a manual for $30 or best offer (including shipping) that looks like it's in great condition and includes the K750-F1. Offer $20 and see what he says. Ed

I bought the same manual from ebay earlier today. I was just hoping for a little direction to get me started so that I can try to get it going before the nice weekend coming up.

Sorry I can't help, your clutch arrangement is different than what I'm used to. The KZ750-F1 has a clutch arrangement like that on the the 750 Spectre and KZ700 shaft. Maybe someone with one of those models will chime in. Ed

Just a shot in the dark.
Do you have that little rectangular cover on what would be your sprocket cover?
Held on by 2 screws?
If you do, look under there.
Sorry, I can't even find a decent picture of a 83kz750ltd to blow up.

MDawnz1 wrote: Just a shot in the dark.
Do you have that little rectangular cover on what would be your sprocket cover?
Held on by 2 screws?
If you do, look under there.
Sorry, I can't even find a decent picture of a 83kz750ltd to blow up.

The F1 has a different setup. Here's what the sprocket cover looks like. It doesn't have that little access cover that so many other models have. Ed

As 650ED just mentioned, the F1 is a bit different. There isn't a window in the cover and there doesn't appear to be anything underneath it that is easily accessible as well.

I've tried to place the clevis at diffent points on the splined shaft to see if I could get a different result but haven't had any luck.

Before the old cable split, the clutch worked perfectly. The only thing I changed was the cable and I removed the clevis from the release shaft.

This is for 650ed.
You seem to have all the exploded drawings,
can you help us PLEASE with one of the clutch actuator?
Thanks

Mike

Below is the diagram for the whole clutch for the KZ750-F1. I get my diagrams (with a few exceptions for KZ650 stuff) from Kawasaki.com. Here's how; let me know if you get stuck navigation the site and need help.

Go to Kawasaki.com. On left side put cursor over "Owner Information" then on drop down menu click on "Parts Diagrams." The click "Continue" next to "Motorcycles" and click on model/year/etc. on drop down. Once you get the list of parts for your bike you can click on the category of parts - such as "Air Cleaner" and you will see a diagram of all the parts for that category. Then when you click on an actual part number on the list under the diagram it will say if the Item Status is "Active." If it is “Active” Kawasaki still sells the part through dealers. Also, at that little page you can click on the yellow highlighted question mark for a cross reference of which bikes share that part or click on the red highlighted S to see earlier part numbers for the same part.
If you want to change bike models you can enter the new model at the top. Also, you can put in just the first part of the mode (i.e. KZ750) and it will list all the years and sub models. You also can put in a part number up top and switch the word “MODEL” to “PART NUMBER” using the little drop down in that box. If you do that it will show all the models that part is used on.
Ed

83KZ750LTD wrote: As 650ED just mentioned, the F1 is a bit different. There isn't a window in the cover and there doesn't appear to be anything underneath it that is easily accessible as well.

I've tried to place the clevis at diffent points on the splined shaft to see if I could get a different result but haven't had any luck.

Before the old cable split, the clutch worked perfectly. The only thing I changed was the cable and I removed the clevis from the release shaft.

I believe this is what your problem would be, this needs to be located on the splines in the correct spot. Is there a reference mark on the Top of the Shaft above the splines?
Also the cable will have an adjustment at mid point in the cable, to take out additional slack, before you adjust at the lever.

There appears to be a reference point on the cast housing where the release shaft goes in. However, there isn't a reference point on the release shaft.

It seems like the longer pushrod is stuck. I can't push it in or pull it out.

I'm waiting on a service manual but I might open up the clutch cover tonight or tomorrow to see where everything is hung up. This is my first time working with a motorcycle clutch so I'll be taking a lot of pictures.