1982 Kz1000 LTD clutch problem

So im new to kzrider.com. I have a 1982 kz1000 that i just bought for 800 dollars. It has not ran in about 6 months. The previous owner had taken it apart to replace the stator and never put it back together. I got it and put the stator back on some new gas and had it running in no time. The problem I am having is with the clutch. I adjust it according to the manual. Pull the lever in and I hear a pop and lose all tension on the lever. I noticed it is popping out at the sprocket cover. I know clutch plates have a tendency to stick together after not being in use for an amount of time. So what Im thinking is they are so stuck together that pulling the lever is not enough to spread them apart. Any help on this would be appreciated before i start pulling the clutch basket apart.

It sounds like the "RELEASE-COMP-CLUTCH " that is located under the counter shaft cover is not working correctly or its out of adjustment, Take that cover off and have a look. The three ball "RELEASE-COMP-CLUTCH " will act like that if they are not correctly positioned.

One way to see if the clutch plates are not stuck together is (with the engine OFF) put the bike in 1st gear, pull in the clutch, and rock the bike forward and backward the try to roll it forward. If the bike seems to move fairly freely the plates are not stuck. If the bike will not roll the plates may be stuck or the clutch is out of adjustment or not operating properly. If the plates are stuck you should be able to free them up by rocking the bike forward and backward wit the clutch pulled in. Ed

So here is the update. I pulled apart the release comp clutch and it looked alright i believe. re adjusted the clutch rolled it back and forth seemed to work. Got it started and into first with the clutch pulled in had no problems wasn't crawling or anything. Took it out on the road and a few minutes later the clutch popped again and i lost all tension in the cable. Cable seems to not be broken. Not sure whats going on yet. I will update once i take it apart again,

There are two different designs of clutch release mechanisms used on those engines. You may be adjusting it using the wrong protocol. Does your engine have the ball and ramp release or the steep acme thread release?

Ball ramp release I believe. Three ball bearings in a plate. I'm starting to think the cable is just to stretched out. I re adjusted it again rode it around for a bit then it happened again. Its no longer popping out at the sprocket cover. Its just losing all the tension.

If it's the ball and ramp style you're adjusting it too tight and when you pull the clutch all the way in it is simply locking itself in the fully release position. The cable is either broke or it isnt they really dont stretch and any stretch can be taken out in the middle of the cable or at the bar end. Next time adjust it so you have more free play, (1/8" between the end of the lever and the perch) and see if it does it again, if so put a little more slack in it. The amount the release needs to push the pushrod is only what is needed to spread the clutch discs apart

A new cable is always a good idea. Take a look at your clutch lever and pivot bolt too. All these parts degrade over time and most folks never lube them at all.

Can't expand any on the possibilities, but one possibility that isn't is stuck plates. What happens when plates stick is the lever pulls in fine, feels fine, all just as normal, but the plates are locked and won't disengage. So the scenerio that happens is you pull in the clutch, drop the bike in gear, it lurches forward as if you hadn't pulled it. I don’t believe this matches your problem.

Definitely adjusting it to tight. Seemed to fix the problem... but now my oil light is on and its smoking alot. white smoke. Thanks for all the help.