Clutch pushrod adj.

I have read recently about a 2nd clutch adjustment the pushrod; which may be the source of some recent problems I have experienced. When it is cold out or the bike is not thouroughly warmed up the clutch can slip above 5,000 rpm. From what I understand this adjustment should be made every few thousand miles .Which is why Isuspect that this might be my problem. When I got the bike (1981 KZ1000 LTD) it had 11,000 mi it now has 30,000 and has never been adjusted.. Does adj. have to done warm??? All the way in 1/2 turn out I gather. Anybody have any other details I should be aware of ?? Thanks in advance for any comments

Sounds good to me.

All the pushrod does in adjustment is for the most part change your freeplay at the lever similar to adjusting slack on the in line adjusters. Sure there is more to it, but basically it is not a magical adjustment. If you have the correct free play at the lever, adjusting everything different is not going to change anything.
As to adjusting every 5000 miles :laugh: No need. I've got over 300,000 miles on KZs, even the one with 160,000 miles the pushrod has never been touched, original clutch and all still function fine. Some guys go all ape shit over this adjustment, but to me there is only one reason to ever have to adjust, and that is if some inept goober fooled with it before.

I agree there's no magic to it, but if the pushrod is adjusted too tight it will make the clutch slip no matter how the cable is adjusted at the lever or the mid-cable adjuster. This is because if it is adjusted too tight the pushrod will prevent the clutch springs from applying full pressure to the clutch plates. Ed

Clutch push rod adjustment -- Need and Purpose
[This is a 1 minute job from start to finish, maybe 2 minutes the first time.]

The FSM covering Z1 and KZ900 includes a periodic maintenance chart requiring clutch push rod adjustment at 2000 mile (3000 km) intervals and explains the need therefor in separate text, which explanation is quoted verbatim as follows:

Besides cable stretch, clutch plate wear also causes the clutch to go out of adjustment, with a decrease in push rod play. Due to this wear, the push rod gradually moves closer to the clutch release lever (at the lower end of the clutch cable) until it touches the adjusting screw. When the rod is touching the screw and therefore has no play, the clutch will not engage fully and clutch slippage will occur. Note that the clutch push rod does not necessaily have play just because the clutch hand lever has play, and so hand lever play alone cannot be used to determine whether or not the clutch requires adjustment.


The FSM covering '77-'79 KZ1000's includes a periodic maintenance chart requiring clutch adjustment at 5000 km intervals, and explains the need therefor in slightly different language, which explanation is quoted verbatim as follows:

Clutch plate wear also causes the clutch to go out of adjustment. This wear causes the play between the push rod and the adjusting screw to gradually diminish until the push rod touches the adjusting screw. When this play is lost, the clutch will not engage fully, causing the clutch to slip.
NOTE: Even though the proper amount of play exists at the clutch lever, clutch lever play alone cannot be used to determine whether or not the clutch requires adjustment.

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end of excerpt

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While the clutch may indeed be worn out with plates needing replacement, it isn't uncommon to overlook or be unaware of the clutch pushrod adjustment feature, especially without a manual. It is worrisome to see anyone of unknown experience, without a manual or failing to consult a manual, proceed with clutch disassembly and plate replacement, without first being aware of and considering the clutch pushrod adjustment.

Where both (1) clutch cable slack adjustment is perfect, and (2) clutch pushrod adjustment is perfect, and the clutch still slips, suspicion is certainly toward the plates being worn and needing replacement. But other things can also cause slippage, even with proper adjustments and good plates, such as glazed plates or improper oil being used in the crankcase.

Good Fortune!