KZP clutch goes away

Hey gang. I'm on a trip near Highlands, NC and my clutch keeps going out. I'll be riding along and go to shift and the clutch lever just lets go like the cable snapped. The cable is not broken.
The first time it happened I took the left cover off and put it all back together and it worked for a few miles before it did it again. Ideas?


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Maybe the adjustment screw is too far in.
Steve

Would that cause it to work fine and then not? I can feel it let go when it does. Almost feels like a broken cable. I can put the bike in gear but it won't go anywhere.
I did adjust the clutch before I left and it worked fine for the ride out here.


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ThatGPzGuy wrote: Would that cause it to work fine and then not? I can feel it let go when it does. Almost feels like a broken cable. I can put the bike in gear but it won't go anywhere.
I did adjust the clutch before I left and it worked fine for the ride out here....

Perhaps the clutch actuator is being over-extended (i.e., pressed beyond its limit). Adding more gap via the clutch pushrod adjustment screw could reduce the range of motion imposed to the actuator when squeezing the handlebar clutch lever because some of the cable movement would be consumed by closing the added gap.

I can put the bike in gear but it won't go anywhere. :huh:

Good Fortune!

Almost feels like something is breaking when it happens. When I took it apart and put it back together again it worked like new - for a little while.


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If it's the EZ pull (ball and ramp). it will go too far and you'll hear a pop. My 350 Honda did it all the time until I learned how to do it. They sell EZ pulls but I did my clutch mod instead.
Steve
kzrider.com/forum/2-engine/601798-clutch-actuator-mod

2001 KZ1000-P Clutch Actuator assembly as shown in the Clutch diagram from Kawasaki.com





Good Fortune!

Thanks everyone. I ended up getting it picked up. It was raining anyway and I didn't want to get stuck on the mtn. especially in a place where there was no place to pull over. Live to ride another day...
I'll take another look at it when I get it home.
Thanks everyone

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Ok Got it back and I think I have this figured out.
When I adjusted the clutch I used my FSM for the KZ1000 clutch adjustment procedure which says to turn the adjuster clockwise until it becomes hard to turn and then back off 1/4 turn. My Clymer KZP manual says to turn the adjuster counter-clockwise. The Clymer manual is correct.
So the adjuster was clocked too far over and eventually (160 miles) it just over-extended.
I could have fixed it on the side of the road but it was raining, I was in a poor cell reception area and the wife was none-too-happy.
I'm glad it was not an expensive fix but now I get to work on the low oil pressure and oil leaks.
Thanks again Everyone.
Jim