CLUTCH ISSUES

Hey there fellow bikers, I am in need of some advice. 1982 KZ1000J. After rebuilding the engine and reinstalling, my clutch lever was extremely difficult to pull. It did work but I wanted to adjust the tension and play at the lever. I removed the adjustment screw cover and attempted to turn the screw per the manual. The manual stated to turn the screw in until it became hard to turn so I tried to back it out to adjust per the manual. It was very difficult to turn in either direction. I then pulled the cover to ensure nothing was hung up. While loosening the bolts the cover pushed away from the crankcase about 1/8" to 1/4". After I made sure that nothing was binding I placed the cover back on. The cover was still away from the crankcase and needed the bolts to pull it back in. The dowel pins were aligned properly. Is there anyway that the clutch push rod could be hung up somewhere. I would assume that the cover should go on without any resistance and without needing the cover bolts to pull it in. Any help will be greatly appreciated. I have owned several bikes and never had a clutch lever that pulled this hard. Thanks in advance, stay safe and be well. Jon

I’d back off on the adjusted bolt before assembling the counter sprocket cover. Before you do, you should pull the push rod out and and check it for straightness. Install the cover and adjust per manual. 

You may have one of those clutch adjusters that have to be turned counterclockwise to tighten and clock wise to loosen.

Did you change any part of the clutch when you did the rebuild?  Is it the same push rod?  Did you change anything with the clutch pusher mechanism on the chain cover?  

By richard-GPZ:  You may have one of those clutch adjusters that have to be turned counterclockwise to tighten and clock wise to loosen.

Yes, his should be the type. 
From the 1981-83 FSM. 82 Supplement section. 10-18. Counterclockwise first until hard to turn. Then clockwise 1/4 turn. 
The manual bolded the two words to hi-light the direction.  The owner's manual probably has the procedure.

Martin is correct. Kawasaki started installing the EZ pull in the 1000s in 1982. The 1981 J engine had the older mechanism used in the Z, KZ and MKll engines.

You said the lever can still be pulled
but it's very difficult

Any chance Barnett clutch springs were installed during the rebuild?

I did back the screw all the way out when I had the cover off. Per the manual after the cover is back on it says to screw the adjusting screw in until it gets hard to turn. Since I have to pull the cover in with the bolts the screw will not turn either direction. Haven't checked the rod yet but thats next. Thanks for the reply and advice.

The clutch plates are original. Thanks for the advice though

All parts are stock. I'm going to pull the rod and check for straightness. Then I'm going to pull the clutch housing cover and make sure all is well in there. Hotter than Hades out so I'm going to wait until it cools down a bit. Thanks to everyone for your thoughts and ideas. It is much appreciated.Jon

Is the clutch working at all? Not sure if it’s even possible but did you by mistake put the pusher ball in from the wrong side? It should be under the pusher on the clutch side? Just brainstorming possibilities. 

Something internal is definitely amiss. The cover should seat fully with no resistance at all.