Clutch - very hard pull

1976 KZ750

My clutch has always been really hard to pull and there isn't much travel. Last time I had the left side cover off, cable inside housing seems really free/ not binding/ etc. I am thinking I need to replace clutch discs.

1. General thoughts on hard pulling clutch/ very little clutch travel.
2. Experiences replacing clutch on one of these.

Thank you.

I don’t know of any way that the clutch plates could cause the problem. I would start by adjusting the clutch using the instructions in the Kawasaki Service Manual. If that doesn’t alleviate the problem I would ensure the clutch cable operates freely when not connected at the lower end, and I would clean and lubricate the clutch release mechanism (see diagram below) and ensure that it operates freely. Other than that, is it possible that a previous owner installed non-stock clutch springs? Ed

I would do exatly what Ed says but in reverse order. Clean that release real good and lube it with something that doesnt collect dirt. Then adjust correctly.
Wayne

650ed wrote: I don’t know of any way that the clutch plates could cause the problem. I would start by adjusting the clutch using the instructions in the Kawasaki Service Manual. If that doesn’t alleviate the problem I would ensure the clutch cable operates freely when not connected at the lower end, and I would clean and lubricate the clutch release mechanism (see diagram below) and ensure that it operates freely. Other than that, is it possible that a previous owner installed non-stock clutch springs? Ed

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I had the same problem on my 750 twin (B4) when it was new. The assembly shown in the picture above went bad pretty quickly. It was set up wrong. There is a "lever" that the cable runs into that has to be set to get most leverage. Hard to explain, but once I got it fixed it was easy to pull.

I would try cleaning and greasing the throw out assembly if a basic adjustment is no help. The picture shows the "tube" piece that has helix shaped grooves that the ball bearings run in. On mine, those grooves were worn.

Thank you. I adjusted clutch and it is way better.