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1982 KZ440 LTD Belt Drive Clutch 17 Jan 2023 07:13 #878909

  • joj2180
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I picked up a 1982 KZ440 LTD last fall for my winter project.  Carbs needed to be cleaned and it would not shift into gear.  Carbs are done, but having trouble with the clutch and identifying what is wrong. 
I have a Kawasaki Service Manual, the parts diagram of the clutch shows a steel ball and clutch push rod.  I removed the clutch plates and there is no steel ball or push rod.  Parts diagram for the D4 model on Partzilla website does not show the steel ball, yet my service manual does.  It appears the service manual diagram shows the D1 version, which from what I can tell is the 1980 or 1981 model year.  The bike was worked on before, so I would not be surprised if pieces are missing.  
Is anyone familiar with the D4 model clutch and possibly provide some guidance?
Thanks!

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1982 KZ440 LTD Belt Drive Clutch 17 Jan 2023 07:49 #878912

  • gd4now
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There is a manual on this site for the 440 with 81 and 82 revisions  kzrider.com/modules/ServiceManuals/kz440.pdf

It appears that in 81 and 82 the clutch cable is located on the right hand side of the engine (clutch side) and not the left side from the earlier models. So there is no push rod and the ball is replaced by a bearing. It has detailed instructions for adjusting cable and release system.  Hope this helps. 
1977 KZ650 B1
Pods and Denco header


This is my Z

OLD KAW OWNERS SMILE ALOT

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1982 KZ440 LTD Belt Drive Clutch 17 Jan 2023 19:00 #878932

  • joj2180
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Yes!  I did not realize there was a supplement to the manual, this is perfect.

Thank you!

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