2000 KZ1000 Replaced Clutch/no lever pressure

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?

Clean, grease and install the ball and ramp actuator. Adjust the screw after installing the sprocket cover then adjust the cable.
Steve

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?

AKA EZ PULL> They're known for that. Inside the sprocket cover where the cable attaches.
Steve

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!

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

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.

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.

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!

Here's a cut and paste from the KZ1000 / KZ1100 Kawasaki Service Manual (not Police bike specific, but probably the same advice). Ed

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

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