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Frozen clutch cable
- Britome
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Attachment image.jpg not found
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- JimB
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The part in the pic when pulled by the clutch cable pushes the clutch rod that then pushes against the clutch plates. Behind that part is a rod with a ball bearing that goes thru the engine. The spring that you see there should be replaced, it helps ensure that the clutch cable is tight but is most likely not causing the sticking. If you take the two screws out you should be able to pull out the cluch rod. I would guess that the rod is actually stuck or the clutch plates. Watch out and don't lose the ball bearing when the rod is removed. If when you take out the rod and it does not appear to be the part stuck then you will have to look at the clucth plates on the other side of the motor and make sure they are not stuck.
I hope this helps.
Jim
1978 KZ1000A2, 1980 KZ1000E, 1980 KZ1000B4 LTD
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- Britome
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- 650ed
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1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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- ZERO
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Only Kawasakis have a soul 1977 Kawi KZ1000 special 2000 Kawi ZRX1100
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- Britome
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I have lost a total of two of what looks like 9 bearings. Seems like they are standard 1/8" steel bearings. I'll order more. I think the bearings had seized which is why it was impossible to pull the clutch lever. I'll order that spring as well.
I'm still feeling my way around this bike. I assume the rod is not the assembly I've been messing with so it is still inside the bike.
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- steell
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The ball bearing you lost were part of the release assembly, and need to be greased, and when you reassemble the clutch release you need to make sure it's clocked to the right position, or it may not have enough travel to release the clutch.
Go to kawasaki.com, or Ron Ayers, or Bike Bandit, or somewhere else and look at the illustrated parts breakdowns, they help you to see how it's assembled and in what order.
KD9JUR
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- martin_csr
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- Britome
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I was just going to ask the best place to order parts. Thx for the info.
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- sbc1320
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1980 KZ1000 LTD-B4(MK II engine) - Progressive suspension, MTC pistons, Dynojet Stage III, all wear items replaced, WFO paint scheme(1978), etc..
Past bikes- 2 1976 Kz900's, 5 1975-76 Honda CB750's, Honda 500 -4, Honda 250, Honda 125, Honda 100, Suzuki RM 250, Honda XL350, Kawasaki KLR 650, etc..
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- 650ed
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Britome wrote: I've got a 78 sr650. Strangely enough, there is nothing in the shop manual that talks about this release mechanism. Odd. The coaching on making sure it is "clocked to the right is very helpful.
I was just going to ask the best place to order parts. Thx for the info.
What shop manual do you have? I ask because if it is the Kawasaki Service Manual take a look under Disassembly - Engine Installed. There it shows how to disassemble and re-assemble the clutch release. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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- Britome
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When I took out the cover, it was obvious that it was with all the mechanicals that the cable was attached to. The clutch was permanently engaged until I took the mechanism off. The arm wasn't moving back into place after the cable pulling it forward.
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