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2000 KZ1000 Replaced Clutch/no lever pressure
- STotten
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02 May 2017 14:03 #760999
by STotten
2000 KZ1000 Replaced Clutch/no lever pressure was created by STotten
Hi, I just picked up a 2000 KZ1000 former police bike. Only thing that was wrong with it is that the Clutch plates needed to be replaced. I replaced them, and as I was going to the next step of the instructions, I was a dummy and I squeezed the clutch lever while the adjustment screw cover (Left side of the engine) was off. Now there is no clutch pressure.
Can anyone explain what I did and how to fix it?
Can anyone explain what I did and how to fix it?
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- SWest
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- 10 22 2014
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02 May 2017 14:37 #761001
by SWest
Replied by SWest on topic 2000 KZ1000 Replaced Clutch/no lever pressure
Clean, grease and install the ball and ramp actuator. Adjust the screw after installing the sprocket cover then adjust the cable.
Steve
Steve
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- STotten
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02 May 2017 14:43 #761004
by STotten
Replied by STotten on topic 2000 KZ1000 Replaced Clutch/no lever pressure
Hi Steve, Thank you! The ball and ramp actuator, I am not familiar with these (Probably have seen them, just didn't know their names) where will I find these?
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- SWest
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02 May 2017 15:50 #761007
by SWest
Replied by SWest on topic 2000 KZ1000 Replaced Clutch/no lever pressure
AKA EZ PULL> They're known for that. Inside the sprocket cover where the cable attaches.
Steve
Steve
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- STotten
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02 May 2017 16:25 #761008
by STotten
Replied by STotten on topic 2000 KZ1000 Replaced Clutch/no lever pressure
Thank you so much! it might be a few days before I get to it, but I will let you know if it works.
Thank you!
Thank you!
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- Gordoninnc
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03 May 2017 05:16 - 03 May 2017 05:18 #761041
by Gordoninnc
Replied by Gordoninnc on topic 2000 KZ1000 Replaced Clutch/no lever pressure
STotten, I just went through this about three weeks ago. I'm new to the site and I'm not sure how to post a link to the thread but you can search for it.
Forum - Technical Forums- Engine - 2002 KZ1000 Police Clutch problem
Search for 2002 KZ1000 Police Clutch problen, author Gordoninnc.
You will see some photos of the "ball and ramp" set up and it should help to shed some light on the subject.
I'm going to ask.....but you said you replaced the clutch plates. Both the friction and the plain??? You probably knew but the friction are directional and it's thought that the cut edge of the plain plates should face the pressure plate. Just saying.
Take care and good luck, seems to be several KZP owners here on this site.
Gordon in NC
Forum - Technical Forums- Engine - 2002 KZ1000 Police Clutch problem
Search for 2002 KZ1000 Police Clutch problen, author Gordoninnc.
You will see some photos of the "ball and ramp" set up and it should help to shed some light on the subject.
I'm going to ask.....but you said you replaced the clutch plates. Both the friction and the plain??? You probably knew but the friction are directional and it's thought that the cut edge of the plain plates should face the pressure plate. Just saying.
Take care and good luck, seems to be several KZP owners here on this site.
Gordon in NC
Last edit: 03 May 2017 05:18 by Gordoninnc.
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- martin_csr
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03 May 2017 06:54 - 04 May 2017 04:11 #761048
by martin_csr
Replied by martin_csr on topic 2000 KZ1000 Replaced Clutch/no lever pressure
When installing the cable, there should be a spring & cotter pin at the clutch release mechanism to keep the cable end seated.
A 1/16 x 1" cotter pin is a close match. I hate rust, so I install a ss cotter pin.
A 1/16 x 1" cotter pin is a close match. I hate rust, so I install a ss cotter pin.
Last edit: 04 May 2017 04:11 by martin_csr.
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- Nessism
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03 May 2017 07:10 #761050
by Nessism
Replied by Nessism on topic 2000 KZ1000 Replaced Clutch/no lever pressure
Remove sprocket cover
Remove ball and ramp device (the small part the clutch cable attaches too)
Clean old grease and apply fresh
Install ramp device such that the angle of the arm is roughly 90* to the cable path. Most likely when you pulled the lever the ramp jumped over the top, moving it too far CCW.
Install sprocket cover
Adjust ramp device using screw on cover, then snug down the lock nut.
Remove ball and ramp device (the small part the clutch cable attaches too)
Clean old grease and apply fresh
Install ramp device such that the angle of the arm is roughly 90* to the cable path. Most likely when you pulled the lever the ramp jumped over the top, moving it too far CCW.
Install sprocket cover
Adjust ramp device using screw on cover, then snug down the lock nut.
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- STotten
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03 May 2017 07:37 #761054
by STotten
Replied by STotten on topic 2000 KZ1000 Replaced Clutch/no lever pressure
Hi Gordon, thank you for the tip. I didn't actually know that the friction plates are directional. I will uninstall and reinstall. How do you know which direction they are supposed to face?
Thanks!
Thanks!
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- 650ed
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03 May 2017 07:53 #761056
by 650ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Replied by 650ed on topic 2000 KZ1000 Replaced Clutch/no lever pressure
Here's a cut and paste from the KZ1000 / KZ1100 Kawasaki Service Manual (not Police bike specific, but probably the same advice). Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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- Gordoninnc
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03 May 2017 10:23 #761070
by Gordoninnc
Replied by Gordoninnc on topic 2000 KZ1000 Replaced Clutch/no lever pressure
Crap.......getting old isn't for sissies so I'll need to get back home and check my notes. But I "think" our KZ1000 Police's clutch runs counterclockwise. So when your looking at the friction plates as installed in the basket the grooves in the palate will make a / forward slash???
I swear I just just got through doing this but I'm not 100% sure of that but will check again tonight.
Plain steel plates......have a rounded edge and a sharp edge.....easy to feel. Install the sharp edge toward the pressure plate.
I'll report back after I review my notes.........I suffer from CRS.
Gordon in NC
I swear I just just got through doing this but I'm not 100% sure of that but will check again tonight.
Plain steel plates......have a rounded edge and a sharp edge.....easy to feel. Install the sharp edge toward the pressure plate.
I'll report back after I review my notes.........I suffer from CRS.
Gordon in NC
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- Gordoninnc
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03 May 2017 19:13 - 04 May 2017 03:38 #761124
by Gordoninnc
Replied by Gordoninnc on topic 2000 KZ1000 Replaced Clutch/no lever pressure
Okay, that was right, clutch turns counterclockwise so the grooves in the OEM friction plates make a / (forward slash) as viewed looking into the clutch basket. It's supposed to help the plates shed oil.
Good luck...Gordon in NC
Check out this thread for photos of the ball and ramp mechanism ....KZ1000 Police
www.kzrider.com/forum/2-engine/605632-20...problem?limitstart=0
Good luck...Gordon in NC
Check out this thread for photos of the ball and ramp mechanism ....KZ1000 Police
www.kzrider.com/forum/2-engine/605632-20...problem?limitstart=0
Last edit: 04 May 2017 03:38 by Gordoninnc.
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