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TOPIC: 1983 KZ750 L3 clutch rebuild??

1983 KZ750 L3 clutch rebuild?? 02 Dec 2019 18:02 #814857

  • chuck hahn
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I am looking for a rebuild tutorial to replace loose dampners in the outer basket. Im pretty sure I should NOT be able to move the gear around by hand. I checked the backlash per the service manual between the basket gear and the secondary gear.. alls well there. Only thing that stands out is the basket gear being abnormally loose.

Are there springs in there or rubber pucks like my 77 KZ650 B1 has??

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1983 KZ750 L3 clutch rebuild?? 03 Dec 2019 11:02 #814883

  • gazzz
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Here is my version of tutorial for KZ650 clutch basket:

www.kzrider.com/forum/11-projects/610746...acer?start=60#810400

Partzilla shows that clutch basket for KZ750 L3 has same part number as Zephyr 750 . Thus its built is similar to KZ650 clutch basket: damper rubbers are same but (if I remember it correctly) 750' baskets have paper gasket under rear metal cover.
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com

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1983 KZ750 L3 clutch rebuild?? 03 Dec 2019 17:01 #814893

  • Nessism
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I performed a similar rebuild as Gazz only instead of screws to hold the basket together the old rivets were welded.

www.kzrider.com/forum/11-projects/604901...ject-thread?start=40

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1983 KZ750 L3 clutch rebuild?? 03 Dec 2019 18:47 #814900

  • chuck hahn
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I did my 650 with the screws and got pucks from Steve. But i dont see a members list to send him a PM. Anyone know how I can get in touch with him again???


EDIt...forgot he was on the 650 forum..Thanks for your reply Ed. I have sent him an email

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1983 KZ750 L3 clutch rebuild?? 11 Dec 2019 05:58 #815213

  • Stu23
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Hi. I've rebuilt my clutch basket (ZR750) using TurboSteve's rubbers and his suggested method (tapping and loctited, countersunk bolts).
Clutch is working fine, but has that not-so-wonderful, old Ducati-style, bag-of-spanners rattle when the clutch is pulled in neutral. As I never rode the bike before I fixed it, I assume this isn't normal?
Any idea what could be loose in there? Just normal play between plates and basket or is my carefully reassembled basket about to explode?
I'll pull it apart and have a look, just wondered what I should be looking for!

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1983 KZ750 L3 clutch rebuild?? 11 Dec 2019 10:48 #815231

  • Nessism
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The primary drive chain makes a fair bit of (normal) noise at idle.

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1983 KZ750 L3 clutch rebuild?? 11 Dec 2019 14:05 #815243

  • Stu23
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Would it change with the operation of the clutch? This is only rattling when the clutch is pulled in.

The primary chain was well within limits when I refitted it... about 8mm play, if I remember, service limit is 25mm.

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1983 KZ750 L3 clutch rebuild?? 12 Dec 2019 14:01 #815282

  • gazzz
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Would it change with the operation of the clutch? This is only rattling when the clutch is pulled in.


That is definitely not normal. I ride my 1991 Zephyr 750 with old damper rubbers in clutch basket and in damper hub on secondary shaft. With carburetors synchronized primary chain slightly rattle on idle but its sound doesn't change significantly when clutch pulled. In my opinion the simplest way to solve the issue is to pull off clutch cover (that may be done even without oil draining : on side (kick) stand with wooden blocks under both wheels) and check what might be wrong.
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com

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1983 KZ750 L3 clutch rebuild?? 13 Dec 2019 02:38 #815291

  • Stu23
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Thanks, Gazzz. Yep, going to do that anyway. Already had it apart twice, before I heard it rattling.

Didn't need the wooden blocks last time, but I've topped the oil up since then :whistle:

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