KZ900 Pushrod Not Moving

I decided to start a new thread on this since I have a different bike/year than the one in this  thread . This is a 1976 KZ900. I have the new clutch cable installed and it seems to be functioning properly. The worm gear inside of the other gear rotates in and out smoothly. It only rotates out about 1/4 of an inch. I assume that is normal, but it's hard to know since the manual is so sparse on info when it comes to the clutch cable and adjustment. I have also made adjustments so that I have 1/8 inch of play at the clutch lever before the worm gear engages the pushrod. The problem I have is that the push rod will not budge at all. I did remove it to cleanup the drive sprocket and that whole area which was caked with grime and dirt over the years. I've been slowly working on this bike for a long time, and now I can't remember if the clutch ever actually functioned. The bike has never run...

Any thoughts on where to start?

You will find it very difficult to move by hand.  You need to use the clutch lever to move it.  If it still doesn't move then I would pull the clutch cover on the opposite side of the bike and check everything.  Something may be stuck...plates maybe?

Yes, I am using the clutch lever to push the rod and move the plates. 

Is the set screw/nut under the sprocket cover properly adjusted?  What do you feel when you pull the clutch lever.  Is there any resistance?

wrote:

You will find it very difficult to move by hand.  You need to use the clutch lever to move it.  If it still doesn't move then I would pull the clutch cover on the opposite side of the bike and check everything.  Something may be stuck...plates maybe?

I second this,  plates stuck together.

Mike
 

Yes, everything appears to be set correctly. I feel complete resistance when I pull the clutch lever. The rod is clearly not budging. I guess ill open the other side of the bike and post some pictures. 

Here is the proper adjustment process 

 

Is the release cam orintated correctly.

 

Here is more to read.

I had the same problem with a kz1000 that sat and the plates were stuck like mentioned earlier.

The clutches on our Z1's usually stick after sitting a few years.  Haven't learned a way to keep it from happening.  We've always been able to free the clutch by placing the bike on the centerstand so the rear wheel is free to spin, start the motor & engage first gear, then give it a little throttle while simultaneously holding the clutch lever in & riding the rear brake.  It's much gentler to the gear dogs than slamming it into 1st gear with a stuck clutch when stationary on the ground.

Clutch pushrods have been known to bend.  Once bent, they just flex.  Lay the pushrod on a flat surface & roll it.  If it's bent replace it.

Good Ridin'
slmjim & Z1BEBE

The bike is not in running condition yet. I will review those procedures and make sure I have done this correctly. Here are some pictures though: