Clutch question. 05 KZ1000P

Installed all new friction and metal plates. Soaked all in engine oil before installing. There is no oil in the engine at this time. Installed sprocket cover yesterday. Checked adjustment on cable and adjustment on cover. All Good. Clutch lever has 1/4 to 1/2 inch play. The new springs required a little more effort but seems okay.

Cannot turn wheel by hand with clutch pulled in. Put a block under wheel and turned engine over by hand. Clutch did slip,,, did not try to go over block. Release clutch, there was no slip. Could not test in 2nd gear or the rest as Kawasaki's neutral lock system will not allow an upshift. I did test all gear shifting after reassemble, spinning output shaft and it shifted flawlessly.

Questions for thought. Should I consider this normal,,, that as soon as oil starts splashing around with the engine running it will likely work fine (my thoughts) or should I remove cover, reinspect my work. There were 9 friction and 8 metal. Installed with friction first, then metal, ending with friction. These are standard Kawasaki parts.

Cannot see how I could bungle this up!

Give the engine a good heat cycle to oil,move and set all parts for around 15 minutes....

1/4 to 1/2 of an inch play at clutch lever is way too much.

I believe free play at clutch lever should be more like an 1/8 of an inch.

Dr. Gamma wrote: 1/4 to 1/2 of an inch play at clutch lever is way too much.

I believe free play at clutch lever should be more like an 1/8 of an inch.

I'll correct that and see if it helps....

Scirocco wrote: Give the engine a good heat cycle to oil,move and set all parts for around 15 minutes....

That's what I am thinking. I have rebuilt engines but never have I had to change out the clutch plates. I changed these out because three of them were blued indicating extreme heat. A cop bike,,, likely abused. They sit on the side eating doughnuts and drinking pure caffeine then when a sucker passes too fast they fire it up,,, gun it once,,, then burn out. The oil probably never had a chance to circulate. lol...

ken19 wrote:

Scirocco wrote: Give the engine a good heat cycle to oil,move and set all parts for around 15 minutes....

That's what I am thinking. I have rebuilt engines but never have I had to change out the clutch plates. I changed these out because three of them were blued indicating extreme heat. A cop bike,,, likely abused. They sit on the side eating doughnuts and drinking pure caffeine then when a sucker passes too fast they fire it up,,, gun it once,,, then burn out. The oil probably never had a chance to circulate. lol...

Hope Rick H doesn’t see this. He might have a different accounting of the day in the life of a motor cop.

Mikaw wrote:

ken19 wrote:

Scirocco wrote: Give the engine a good heat cycle to oil,move and set all parts for around 15 minutes....

That's what I am thinking. I have rebuilt engines but never have I had to change out the clutch plates. I changed these out because three of them were blued indicating extreme heat. A cop bike,,, likely abused. They sit on the side eating doughnuts and drinking pure caffeine then when a sucker passes too fast they fire it up,,, gun it once,,, then burn out. The oil probably never had a chance to circulate. lol...

Hope Rick H doesn’t see this. He might have a different accounting of the day in the life of a motor cop.

It's something very scarce in this country today... humor.