Clutch issues...

I was working on my clutch setup yesterday on the 79 KZ 400, and after getting everything connected and the side cover back on the engine...pull the clutch lever, and there is no resistance at all...

What I mean by this is that the linkage on shifter side does not seem to be working properly, or there is something wrong on the clutch basket side and I don't know where to begin. After pulling the clutch lever, and taking off the shifter side cover, the linkage seems to not be where its suppose to be, when it was before pulling the clutch lever...

any suggestions would be great!

Mike

Is the ball bearing still there? And is the pushrod seated correctly?

Lots of good info on kawasaki.com, including parts diagrams, part names, part numbers, models sharing same part, availability, etc. Here's a link for help with navigating the site and finding information.

www.kzrider.com/forum/13-bike-related/37...imitstart=0&start=20

This link is supposed to allow free download of a service manual.

www.kz400.com/WorkshopManFrameset-5.html

Good Fortune!

steel ball and plunger are all there. took clutch basket off to make sure everything on that side was good. I'm thinking there is something missing on the linkage where clutch cable connects to...and it's not quite reaching the tip of the pushrod...

my question is...what is #5 in the diagram above? I'm clearing missing whatever that is.

79Bobber wrote: steel ball and plunger are all there. took clutch basket off to make sure everything on that side was good. I'm thinking there is something missing on the linkage where clutch cable connects to...and it's not quite reaching the tip of the pushrod...

my question is...what is #5 in the diagram above? I'm clearing missing whatever that is.

Just guessing, but #5 might possibly be clutch release oil seal part number 92049-1003 that's shared on some 67 Kawasaki models.

Would confirm this by checking at the kawasaki.com website link earlier provided.

Good Fortune!

I tried accessing the site with my phone (was not able to get to a computer at that time) and was not successful.

I still have not figured out the clutch issue...after careful inspection, all of the parts are there. Not sure where to turn for the problem now...

One possible cause for the reported clutch issue is that the adjustment screw movements were erroneously reversed and therefore incorrect for the KZ model at hand.

Could repeat the clutch push-rod adjustment, being sure to first turn the adjustment screw out counter-clockwise until it becomes hard to turn. Then turn it back in clockwise a 1/4 turn. Then tighten the lock-nut.

The correct order of turning isn't instinctive, as it may seem weird that turning out counter-clockwise closes the gap.

Other KZ models have clutch actuators designed whereby the push-rod adjustment is performed in the reverse order of turning direction.

Good Fortune!

Good Fortune!

Have already tried adjusting in all 3 places of the clutch setup. When you pull the clutch lever, it does nothing, but spring back. For some reason, this linkage is not pushing the push rod when clutch lever is pulled...

Here's part of what's included on pages 62 and 63 of the manual that's downloadable via the earlier posted link:

www.kz400.com/WorkshopManFrameset-5.html








Good Fortune!