TOPIC:

I have a 91' KZ Police, a little while back I took the Sprocket and transmission covers off to replace an oil seal. After I got everything buttoned back up, attempted to go for a ride. Started up no problem. The clutch lever did feel a bit stiffer than before. Put it in gear, released the clutch with some throttle and proceeded to go no where. I shut it off. Put it on the center stand and started it again. The back wheel did spin slowly in gear but when I stopped it with the rear brake the bike did stall. I have since replaced the friction plates, the springs, and everything under the sprocket cover. I didnt replace the basket or the clutch push rod because both looked fine. have taken the transmission cover off again and inspected everything to make sure it was in the right spot etc. Today I tried to get it to stall by starting it putting it in gear and the loosening the bolts on the sproket cover taking all pressure off the clutch push rod. No joy, back tire just sat there not spinning with the engine continuing to chug along.

I am at a loss of what to look at now, or why this started happening to begin with.

Before you replaced everything. I would have said to check the clutch actuator carefully to be sure it is properly lubricated, operating smoothly and properly oriented. Then be sure to properly adjust the cable in the exact method outlined in the factory service manual. The proper order of adjustment is important.
Now that you have replaced so many things, many more culprits have been introduced. Did you use genuine Kawasaki parts?

I have used all Kawasaki OEM parts minus the friction plates that I got from Z1enterprises. I did follow the clymer book for the adjustments. Again even when I have loosened the cover to remove all possible pressure on the push rod the engine still wont stall in gear despite the back tire not rotating or the rear brake engaged

Did you soak the new friction plates in oils before installing?

I did, and I would assume that I would have issues with my clutch releasing vs not engaging if that was the issue

Maybe let it idle a bit? while working the clutch?

And you used Jaso rated oil? Did you make sure the first and last disc installed were friction? and you have the correct number of each.

I did a one for one and installed in the same manner that they came out. This issue did present itself prior to me swapping the friction plates, but as this was a clutch issue and I assume that the plates hadnt been changed in quite some time I thought it a good time to tackle that while I inspected the basket and other stuff under the clutch cover

If i read that correct the bike wasnt rideable before you did the work?

It was ridable, I had an oil leak so replaced the seals on, this started once I put everything back together.

Im not really familiar with your bike but I think the J1000 are all pretty much the same, try this manual it might help.

kzrider.com/modules/ServiceManuals/Kawas...Service%20Manual.pdf

From you description of how the bike is acting. It sounds like the clutch is slipping.

EDIT; I just learned something reading the manual. The friction plates are directional. Not that way with my Kz engines.

Did you get them orientated directionally correct?

Where did you find them being directional? Prior to putting them in I was worried that may be the case and looked at them for a hot minute trying to see if there was a difference from one side to the other. I will have to pull the cover off to take a look at it.

So I know the clutch is slipping. When I pull the cover off to check the plates, I'll make sure that my springs are set to proper torque.

Its getting to be dang nice riding weather down here.

Edit: I will try an oil change too. For some reason I think this last time I ended up putting Pennzoil in it which isnt my normal choice.

I appreciate the help and will update as I go through it.