TOPIC:

This clutch pusher kit looks to be the same design they used in the 1984 KZ700.

 

Thanks. I wish I'd known before I spent a fortune on this after market one. I'll search the interweb and see if I can find any more info on the '84 KZ700 one. Cheers.

My 1981 750E uses the same mechanism. 

It was used on a lot of models, however, the part that the cable connects to evidently comes in two versions. One part number fits the 550s and 750 four cylinder engines, while the other number is listed for the 1000, 1100, and 750CSR twin. I wonder if one is a tad thicker than the other, thus requiring a different pushrod?

www.partzilla.com/product/kawasaki/13102...45e129b47a54be3be915

www.partzilla.com/product/kawasaki/13102...b98a997ab2f619aa19d9

I feel it has something to do with the bearing or the bearing holder inside. The pushrod is now being engaged and disengaging the clutch. But something is going on in the Easy Clutch itself that is causing it to let go and end up with a limp clutch lever after 4-5 pulls of the lever..

Do you have the spring over the cable between the sprocket cover and actuator lever?

 

Yes thats in place.

The system adjustment needs to be set so the PMC lever mechanism is sitting right at the bottom of the ramp when the hand lever is out, and the ramp arm needs to be positioned so the cable is pulling at about 90 degrees.  With the arm resting at the base, adjust both the mechanism and the cable free play so you have a little free play at the lever.  If the mechanism is sitting at the base of the ramp it won't jump over the top when you pull in the lever.

wrote:

 There is only 3 positions it can sit. Each position is 120 degrees from the other.

 

I have no experience with this but based on the pictures, there should be 6 positions that the arm can 'sit' based on which way the cup thing is mounted - 3 one way and 3 more with the 'cup' rotated 180 degrees - making the 'arm' rotatable in 60 degree increments.

At this point there's either a defect with the part, or a pre-existing problem with the bike.

the directions provided by PMC are excellent and leave little room for error.  

Nessism. I get what you are saying and I'm pretty sure its sitting right where it should. The arm is pretty close to 90 degrees when its sitting in the bottom of the ramp. It works fine for 4-5 pulls. Just not sure what happens to cause it to let go.
CB900f. I get what you are saying too. But because the actuator arm can only be pointing one way so the cable can be connected. There is only 4 positions it can be. I tried turning the gold holder 180 degrees. But the arm was either too far forward or too far back and was hitting the aluminium casing. As per instructions it sits pretty good.
MoveOver. The clutch works fine with the factory bits in it. Just a bit tough on my old wrist. As for the instructions. They might be excellent and leave no room for error, if you can read Japanese. Blipco did very kindly give me a translation which was a direct translation and quite hard to understand. But was helpful in letting me know I was turning the slotted screw the wrong way to engage the pushrod.
​​​​​​​Again. Thanks guys for all you help.

Last two guess. Are you installing the cotter pin that retains the cable end. Have you checked the pushrod for a bent. Something sounds like maybe, the release isn’t fully returning, the cable end might be coming out of its seat and catching the shoulder of the farrell. Next pull the release is advanced, but cable is tight again. Another pull and release over advances and the balls jump over the ramp. A bent push rod might not be allowing the release to fully return. Have you watched the action while have an assistant pull the clutch lever. Might give you an idea what’s happening. You might be able to see the release in motion if you remove the chain and sprocket and look into the sprocket cover. Try working the release with it mounted and the sprocket cover off. Does it return fully? Does it seam to function correctly? If components won’t work as an assembly break them down into individual parts and check each function independently.