KZ750 CSR Clutch Suddenly Out

bpchura wrote: Hey all, sorry about the profile information and not telling all about the bike. I have tried many times to update my information but for some reason, the save button on the profile information form doesnt seem to work or do anything at all?

You guys are correct, the bike is a twin. Sorry about not mentioning that earlier.

You need to provide EXACT information about what year and model motorcycle you have. Not all KZ750 twins use the same parts, so PLEASE be specific if you want to ensure you get accurate information. Add it to your signature, but if you cannot be sure to include it in your postings. Ed

Its a 1982 KZ750 CSR twin.

Alright sorry for the confusion everyone. Profile update has worked and all is peaceful with the world.

I don't know anything about the twins, but if the clutch is even remotely similar to the 4 cylinder engine, there is very few possibles for this type problem. Clutch cable 95% of the time. Hard to imagine any other common problems. I once had a clutch hub nut come loose and the whole clutch basket slipped off the shaft. I suppose possible the release mechinism is broken as another possibility, but these problems are few and far between. I wound examine the cable again.

OK. The 1982 KZ750-CSR Twin model is a KZ750-M1. That is the term that you can use when searching parts databases. The clutch mechanism for this model is shown in the diagram below. Ed

Alright I will go through the cable and actuator with a fine tooth comb. Thanks for the diagrams. il have a look at them when I poke around. Thanks again!

Hi BP,
Did you ever resolve your issue? When the pop happens is there suddenly slack on your cable? If so the cable could not be seated right, where the cable enters the case and be snapping back into place. Just a thought.

I have not resolved this issue as of yet. And yes, you pull the clutch and instead of pulling normally,, it pops and then goes totally slack. I checked the mechanism out and it seems fine. I couldnt imagine anything wrong with the actual clutch. Could you provide more detail about your suggestion? I dont recall how the cable attaches into the cover but I will check it out.

That's the EZ pull design. My old 350 Honda had it. It would do the same thing. Are you sure the balls are in the sockets when you set it up? Is the holder loose? If that is what you have, it is possible you are trying to adjust it mid range thus the pop is when the balls drop into the sockets. If you have the worm gear design, the holder could be loose. Ether way, make sure the adjuster is seated all the way in with the adjustment screw all the way loose and the cable loose. Adjust the screw in until you feel it seat, then back it off 1/8 turn. Tighten the cable. See if that helps.
Steve

Hello everyone. I thought I would give an update as I have finally had time to dig into the clutch problem. I first went through the cable and adjusted it perfectly. It is fine and not an issue. I next went through the push mechanism and cleaned out the old grease and got it all back together. Seems to b working fine. I opened up the clutch cover to see if there was anything wrong. When I took apart the clutch, I found two broken friction plates!! One had a small crack but the other was totally shattered!

Obviously that had something to do with the problem. I put everything back together minus those plates while I wait for the new ones to come in. Not surprisingly, the clutch seems to work fine now and is very smooth. Who thinks I solved the problem? I wonder how it works when I have everything back together...

Just curious but how common is the broken friction plate? All other plates seem in fine condition and I dont see why they would randomly break. It may have something to do with the fact that I was riding really hard when my clutch went out..... possibly a rough shift?

i would still recomened a new clutch cable. sometimes they look to be intact but they will fray on the inside. when you adjust the clutch it may have some clutch until it breaks. your clutch cable actuates the pressure plate. Either way it is a simple problem. if you stlii need help let me know. dave

Thanks Dave. I will look into the new cable and let you know if I still have problems.