2002 KZ1000 Police Clutch problem

Gordoninnc wrote: It just so happens I'm headed up there on the 21st.......and will be on 64 from Morganton to Ga. Two Wheels of Suches for an XS Rally.

I'll see you there. Are you bringing the cop bike or an XS?

I have a ratty 1975 650B that I'll be riding and if my brother comes along I'll let him ride the KZP.....if I have it ready. If not I'll put him on a Honda or a BSA.

I pulled it apart tonight and cleaned it up. Looks pretty simple. I am a bit confused because it looks like the adjuster only has one position that will work. I mean there's only one way the cable end of the lever matches the boss for the cable. Am I missing something?

GPzGuy.......you doing the Dogwood?????? Were you there last year??????

Gordoninnc wrote: I have a ratty 1975 650B that I'll be riding and if my brother comes along I'll let him ride the KZP.....if I have it ready. If not I'll put him on a Honda or a BSA....

WAIT - Don't let anyone ride that 1975 KZ650-B! It is the only one ever made and should be sold to Kawasaki for their museum. :whistle:

650ed wrote:

Gordoninnc wrote: I have a ratty 1975 650B that I'll be riding and if my brother comes along I'll let him ride the KZP.....if I have it ready. If not I'll put him on a Honda or a BSA....

WAIT - Don't let anyone ride that 1975 KZ650-B! It is the only one ever made and should be sold to Kawasaki for their museum. :whistle:

Sorry....we were talking about an XS rally.......the bike is a 1975 Yamaha XS650B......and they made and sold a blue zillion of them.

Gordon in NC

Gordoninnc wrote: GPzGuy.......you doing the Dogwood?????? Were you there last year??????

Yeah I was there on Saturday. I was on the ratty XS650 with the girly on the tank.

I was the fellow who broke his clutch cable before the ride started Saturday. Small world.

I'm going to take several photos of this cover/adjuster tonight because I need some direction. The lower ramp is indexed so I can't get that wrong. That places the balls in a single position so I can't mess that up. The way I see it there could only be three options for the lever and only one position makes sense to me. BUT (there I go again) I keep reading where you can get the lever in the wrong position and it can over extend again???????

Photo's to follow.

OH......GPzGuy.....I went home and made sure I didn't break another clutch cable on the XS. It was all my fault for just living with a stiff pull.

Take care and see ya on the 21/22???? I'll be in cabin #5 Gordon in NC

Okay fellows, more than one of you mentioned getting the adjustment lever ( rel;ease- part # 131020 in the wrong position and it over extending again......so I'm looking for some clarification so there's a better chance I get it right the first time.

The case has a tab (for lack of a better term) that locates the bottom ramp.

and the lower ramp has a notch

So I would think the lower ramp is a no brainer

I assume the balls are symmetrical but there is a section cut back from the part that holds the balls. Mine was lined up with the case tab and the lower ramps notch like this.

to be continued....

Hard for me to understand why it's cut that way and not sure if this is correct???

The way I see it since there are three balls and three ramps in the lower ramp the balls can be installed in three different locations. So I have a 33 1/3 % chance of getting this right.

Add a little P-80 to the seal and slip in the release with it's own ramp. (I'll call it the upper ramp)

This is what makes sense to me....this position. (release rotates counter clockwise to elongate)

The section where the clutch cable attaches to the release is lined up with the boss/stop in the case for the cable.

We're back to that 33 1/3% thing again since there are three balls.

This is the second option..... position #2

Hmmmmm cant see that working but I don't know

Option # 3.......position #3

I'm just rotating the release counterclockwise until the balls fall into the ramp in the next position.

What I don't understand (yet) is it looks like there's only one position that will work......what am I missing because I know you fellows have done this before and I haven't.

Thanks in advance......hate to say it but.......this is only the beginning

Gordon in NC.

#1. Grease it good, put it together and RIDE THE PISS OUT OF IT. :woohoo:
Steve

It's different than my 750 but I'll bet it's #1 especially with the way the clevis lines up with the cable boss on the lower right.

The trick is making sure it stays in that position and seated while you bolt the cover back on.

Thanks for the help fellows. The cable should get here today and I should have it buttoned up tonight.

I'll keep a close eye on it as it's going back in to be sure it stays in place.

Thanks again for going to the trouble to reply.

Take care and enjoy the spring ( at least on this side of the world)

Gordon in NC

Jim......FINALLY noticed your PM......sorry I'm not used to this site but I'm learning!!!!!!

Cables showed up last night at 6pm........God bless UPS.

Tool time!!!!!

Gordon in NC