TOPIC:

I'm towards the end of my KZ900 project, when test riding the first time I heard a dragging/scraping sound coming from the front of the bike. At first it sounded like a brake puck dragging but then I noticed that when I pulled the clutch in it went away. After pulling the clutch apart I found two broken friction plates... at first I thought.. good this must be it but then realized this wouldn't account for the dragging noise. I pulled off the clutch basket and saw that there was nothing between the "pusher" and the spring plate. I've never had a Kaw clutch apart before but every other bike I've had has had a thrust washer and flat needle bearing between the two mating surfaces. Looking at the exploded view in the manual I didn't see a needle bearing in there nor did I see it on the exploded view on Bike Bandit. I'm certain the steel pusher isn't supposed to mate up against the aluminum surface of the spring plate. What am I missing here?

Also... since I know the PO was a hack, and now I realize he was inside the clutch probably, I started checking around in there. I grabbed the clutch housing and found a tiny bit of play in it. Also when turning the spline axle coming through the housing, I hear a little play in the gears behind the clutch housing. Is this normal? Thanks in advance for any help you guys can give.

My 78 1000 did not have a bearing as you describe
APE makes such a thrust bearing and I added it during one of my upgrade builds.
When you ad this bearing not so much stress and friction is placed on the ball bearing on the opposite end of the pusher mushroom.
You also have to shorten the rod a bit to fit the new bearing into the same amount of space
Dave

There should be a single steel ball bearing inside the hollow clutch shaft between the clutch pushrod and the spring plate pusher. This allows the pusher to easily rotate with the spring plate.

A tiny amount of play is often seen in the clutch basket buffer springs. Unless one or more clutch basket spring is actually broken, not to worry. Ditto the tiny amount of lash in the tranny.

Good Ridin'
slmjim & Z1BEBE

The OEM pusher does not have a radial bearing as mentioned earlier and problems with the pusher would not quieten when the clutch is pulled in as this would put even more load on it.
All big zed clutches make a bit of noise due to the straight cut gears and the damper springs in the back plate.
Excessive wear in the damper springs or broken springs does cause a lot of chatter which quietens when the clutch is pulled in and this can also break plates so that is where you need to look first

Thanks for the input everyone. I guess I'll just replace the broken plates and put it back together. I'll check the springs first and replace them if needed.