Clutch & cable problems for a '82 KZ 550 A3

It's all mechanical, just a simple set of springs on the clutch compress it, then through the cable and clutch release you release pressure slightly on the springs. May seem goofy, but I'd take the cable off completely, then use your feet like the Flintstones did to get moving, then see if the clutch is fully locked. It's easy to ride and shift without a clutch. If the clutch slips then you know you have problems well beyond the simple cable. If the clutch is locked ok, then the cable install should be a simple process, but if the clutch then slips you are adjusting the cable way to tight.

That's how I got the bike to my friends house after the cable snapped, push started it and matched rpms.

I'll ride it that way in the morning, that way I can know for sure its not the clutch.

Thanks for the idea Ron, and if it doesn't work well then I know its something else.

There is a 3/8" steel ball that can go missing when the push rod is pulled out. See #600 in the Clutch diagram. Also, be sure to turn the clutch release adjusting screw in the correct directions.

Edit: i may have misinterpreted what others have reported about the steel ball - perhaps they meant it can get lost when the clutch is removed from the bike?

martin_csr wrote:

TheDude wrote: I'll re-adjust the adjuster screw in the morning, but it's confusing cause I have no power to the back wheel.

Do you know if pulling out the rod that holds the clutch release have anything to do with the loss of power and connection?

There is a 3/8" steel ball that can go missing when the push rod is pulled out. See #600 in the Clutch diagram.
Also, be sure to turn the clutch release adjusting screw in the correct directions.

How can I find out if the ball went missing?

I did what Ron suggested and did the Flintstone style start, and thankfully the bike rode smoothly w/o a clutch cable.

I adjusted the cable properly to no avail.
The cable is a bit too long (3-5 inches).
Still having some problems.

When I adjusted the cable properly...(1. at the engine; 2. at the middle-adjuster; 3. fine-tuning at the lever)...I was able to shift into first, but there was power to the wheel (started spinning) before I even let go off the clutch lever. And, when I gave some gas to it there was no real power to the back tire.

Is this, because the clutch cable is too long and still has too much slack? (How tight is the lever supposed to be?)

Installing a clutch cable should be easy & a too long cable should work.
If it doesn't seem to be actuating the clutch correctly, then either the cable isn't installed right, or the clutch is messed up (which I don't think it is, since the Fred Flintstone trick worked).

Post a photo of how you have the cable & release mechanism installed at the engine cover (ie, with the cover removed & laying on a box)

My gut tells me you're doing something goofy... if so, you can join the club. :laugh:

Man, I hope I'm doing something goofy and it's not something more serious. I will say that even though this is time consuming and a bit stressful, I know a lot more about the clutch and this bike then I did 2 weeks ago. :laugh:

I'm going to Flintstone 40 miles to my house then work on it tomorrow morning. I'll post pictures then.

How tight is the clutch lever supposed to be?

TheDude wrote: ......................................
When I adjusted the cable properly...(1. at the engine; 2. at the middle-adjuster; 3. fine-tuning at the lever)...I was able to shift into first, but there was power to the wheel (started spinning) before I even let go off the clutch lever. .............

That part sounds normal. Bike on centre stand. clutch lever pulled in. put into first gear and the rear wheel should turn/spin. Not enough to move the bike if both wheels are on the ground but enough to give a tug.

loudhvx has a lot of useful informaion (manuals) in a link he has in his signature
home.comcast.net/~loudgpz/GPZweb/index.html#home

including clutch adjustment for the 550
home.comcast.net/~loudgpz/GPZweb/ClutchReleaseMech.GIF

The ball can only come out on the clutch side. If you never removed the clutch plate, then the ball could not fall out.

loudhvx wrote: The ball can only come out on the clutch side. If you never removed the clutch plate, then the ball could not fall out.

I pulled the rod today and I saw, what looked like to be a steel ball at the end of the tunnel. That's good to know it didn't fall out.

Do you know what that ball does, loudhvx?

I think the ball is there because the mushroom shape pusher that actually presses to release the clutch is likely to spin with the clutch, so they put the ball between the mushroom pusher and the pushrod to more or less isolate the pushrod from the spinning.
Sorry otherwise my ideas to fix your bike are lacking. Normally and by all odds the replace of a cable should be very simple, but a KZ550 expert I am not.

There's a lot I have to learn about bikes...in due time.

It sucks this became such a complex problem, I hope I figure it out soon.