1983 KZ750-F1 (shaft drive four) horrific clutch noise
- LeftyFix
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1983 KZ750-F1 (shaft drive four) horrific clutch noise
27 Dec 2024 04:41
Hello, after the commotion of finally getting the kz750 starter clutch replaced, wiring issues solved, the bike fired up and ran with surging idle (emissions rebreather tubing cracked causing vac leak, eliminated it, capped carbs)
took apart to replace old leaky gaskets
popped in a new oem clutch hub (broke teeth on old one with a clutch hub holder tool from Amazon) , put back together and torqued everything down (clutch wouldn’t disengage at this point while it was off, but figured plates were dry because I forgot to soak in oil), and now I’ve got a horrific noise that sounds like someone's shaking a coffee can full of lead marbles (I wish I had recorded the noise)
now I have opened back up the clutch to check if I missed any components and everything on the clutch blown out diagram is there, so I’m truly at a loss at what I screwed up that caused that noise that wasn’t there before I replaced the clutch hub that had chipped teeth.
The factory manual I have doesn’t cover the clutch assembly steps, and my clymer manual doesn’t cover the funky clutch on the 83 f1 model.
theres also rotational play in the outer clutch basket a good 2 inches I can turn it back and forth. No in or out play that is noticeable. Not sure if that’s normal or not but figured I’d mention it
i didn’t run the bike super long, and didn’t check if noise went away if I pulled in the clutch, so perhaps I just needed to wait longer, but I didn’t want to risk hand grenading the motor it sounded that bad… any advice is welcome, especially if it’s about something I might’ve messed up, or things to check
took apart to replace old leaky gaskets
popped in a new oem clutch hub (broke teeth on old one with a clutch hub holder tool from Amazon) , put back together and torqued everything down (clutch wouldn’t disengage at this point while it was off, but figured plates were dry because I forgot to soak in oil), and now I’ve got a horrific noise that sounds like someone's shaking a coffee can full of lead marbles (I wish I had recorded the noise)
now I have opened back up the clutch to check if I missed any components and everything on the clutch blown out diagram is there, so I’m truly at a loss at what I screwed up that caused that noise that wasn’t there before I replaced the clutch hub that had chipped teeth.
The factory manual I have doesn’t cover the clutch assembly steps, and my clymer manual doesn’t cover the funky clutch on the 83 f1 model.
theres also rotational play in the outer clutch basket a good 2 inches I can turn it back and forth. No in or out play that is noticeable. Not sure if that’s normal or not but figured I’d mention it
i didn’t run the bike super long, and didn’t check if noise went away if I pulled in the clutch, so perhaps I just needed to wait longer, but I didn’t want to risk hand grenading the motor it sounded that bad… any advice is welcome, especially if it’s about something I might’ve messed up, or things to check
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- Nessism
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Re: 1983 KZ750-F1 (shaft drive four) horrific clutch noise
27 Dec 2024 08:13
Sorry to hear about the troubles.
Both the clutch hub and the secondary shaft chain drive sprocket-hub, mount with rubber cushions. Could the excessive free play in the clutch hub be related?
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Both the clutch hub and the secondary shaft chain drive sprocket-hub, mount with rubber cushions. Could the excessive free play in the clutch hub be related?
Ed
Carb O-ring Kits : www.kzrider.com/forum/3-carburetor/61807...-o-ring-kits?start=0
www.kzrider.com/forum/faq-wiki/618026-new-owner-things-to-know
1981 KZ750E2
www.kzrider.com/forum/11-projects/604901...z750e-project-thread
Carb O-ring Kits : www.kzrider.com/forum/3-carburetor/61807...-o-ring-kits?start=0
www.kzrider.com/forum/faq-wiki/618026-new-owner-things-to-know
1981 KZ750E2
www.kzrider.com/forum/11-projects/604901...z750e-project-thread
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- LeftyFix
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Re: 1983 KZ750-F1 (shaft drive four) horrific clutch noise
27 Dec 2024 18:53
You are in fact correct the slop is definitely bad rubbers. Could this potentially be the cause of the noise I’m hearing? It wasn’t occurring before I replaced the clutch hub as far as I could tell.
secondly, is there any way to fix this without drilling out the rivets on the clutch housing? Like a separable reproduction part? (Aside from buying a whole parts bike)
im not particularly equipped or confident in my ability to do so without damaging the aluminum housing
secondly, is there any way to fix this without drilling out the rivets on the clutch housing? Like a separable reproduction part? (Aside from buying a whole parts bike)
im not particularly equipped or confident in my ability to do so without damaging the aluminum housing
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- Nessism
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Re: 1983 KZ750-F1 (shaft drive four) horrific clutch noise
27 Dec 2024 19:30
The clutch hub rebuild was actually quite simple. Grind off the rivet heads, install the new rubbers, use C clamps to hold everything together, and then go find someone with a TIG welder. Weld in 1/4's, or maybe 1/2 way around each rivet, to keep heat down, going around and around until everything is welded up. There is also a tutorial around where screws are used instead of welding. The 750 Turbo site has the info.
Ed
Carb O-ring Kits : www.kzrider.com/forum/3-carburetor/61807...-o-ring-kits?start=0
www.kzrider.com/forum/faq-wiki/618026-new-owner-things-to-know
1981 KZ750E2
www.kzrider.com/forum/11-projects/604901...z750e-project-thread
Carb O-ring Kits : www.kzrider.com/forum/3-carburetor/61807...-o-ring-kits?start=0
www.kzrider.com/forum/faq-wiki/618026-new-owner-things-to-know
1981 KZ750E2
www.kzrider.com/forum/11-projects/604901...z750e-project-thread
The following user(s) said Thank You: sf4t7, howardhb
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- Nessism
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Re: 1983 KZ750-F1 (shaft drive four) horrific clutch noise
30 Dec 2024 05:21
I made contact with the guy selling Viton clutch dampers. He charges $45/set + $9.05 Priority shipping. Cheap. I'm thinking of ordering a spare set, just in case. I bought a set from a different guy that sold through the old 650 site. His/mine are neoprene rubber. I wonder which are better for use in hot oil?
Ed
Carb O-ring Kits : www.kzrider.com/forum/3-carburetor/61807...-o-ring-kits?start=0
www.kzrider.com/forum/faq-wiki/618026-new-owner-things-to-know
1981 KZ750E2
www.kzrider.com/forum/11-projects/604901...z750e-project-thread
Carb O-ring Kits : www.kzrider.com/forum/3-carburetor/61807...-o-ring-kits?start=0
www.kzrider.com/forum/faq-wiki/618026-new-owner-things-to-know
1981 KZ750E2
www.kzrider.com/forum/11-projects/604901...z750e-project-thread
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- LeftyFix
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Re: 1983 KZ750-F1 (shaft drive four) horrific clutch noise
30 Dec 2024 05:31
Went ahead and purchased some from turbosteve84, so should come within a week or so. Will fix that up, soak my plates in oil in the meantime, and update if this fixes my issue when installed
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- LeftyFix
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Re: 1983 KZ750-F1 (shaft drive four) horrific clutch noise
Yesterday 19:51
That was an enormous pain in the rear, WOW! But in the end, it is done and my problem is technically fixed.
to start, the clutch dampers were turbo shrunk, like raisins next to a grape. Attaching vids of difference before and after install.
the awful noise I was hearing went away after I cycled oil through the engine for a good 10 minutes, something just wasn’t lubricated and happy. My clutch also now VISIBLY separates, so if the plates are stuck at this point, I’ll just send it on the center stand and hope for the best.
now onto my final problem, SURGING IDLE!
who knows what it is, but I’m gonna hit the carbs with a clean as much as I can as the previous owner stripped every single bolt on the carb rack. Impact hammer didn’t work so I’m not gonna try to damage it further for now.
also going to take this opportunity to check how my carb boots are looking, because this is where I suspect my issue lies, since I had a kz650 that had the same bad boots.
anyways, thank you for the help! Even if it didn’t specifically fix my issue (it was me being impatient) I learned a lot about the clutch mechanism, and built some better modification skills and my tool variety(I will never do this again)
to start, the clutch dampers were turbo shrunk, like raisins next to a grape. Attaching vids of difference before and after install.
the awful noise I was hearing went away after I cycled oil through the engine for a good 10 minutes, something just wasn’t lubricated and happy. My clutch also now VISIBLY separates, so if the plates are stuck at this point, I’ll just send it on the center stand and hope for the best.
now onto my final problem, SURGING IDLE!
who knows what it is, but I’m gonna hit the carbs with a clean as much as I can as the previous owner stripped every single bolt on the carb rack. Impact hammer didn’t work so I’m not gonna try to damage it further for now.
also going to take this opportunity to check how my carb boots are looking, because this is where I suspect my issue lies, since I had a kz650 that had the same bad boots.
anyways, thank you for the help! Even if it didn’t specifically fix my issue (it was me being impatient) I learned a lot about the clutch mechanism, and built some better modification skills and my tool variety(I will never do this again)
The following user(s) said Thank You: Wookie58
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