77z1000 complete clutch replacement

  • Oldman67
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77z1000 complete clutch replacement

08 Jun 2026 17:46
#924720
So I have decided to replace my chatterbox of a clutch with a new APE Track king clutch including a rebuilt clutch basket heavy duty extra plate clutch kit with needle bearing never seize clutch pusher my question is how do you go about removing the clutch basket from the shaft once you have the cases split I can’t find this process in the workshop manual are there any videos out there showing this procedure
tia for any assistance 

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  • TexasKZ
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Re: 77z1000 complete clutch replacement

08 Jun 2026 20:48
#924724
An impact wrench is the easiest way to get it off. 
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/forum/11-projects/620336...amateur-build-thread

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  • StreetfighterKz
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Re: 77z1000 complete clutch replacement

08 Jun 2026 21:23 - 08 Jun 2026 21:32
#924726
how do you go about removing the clutch basket from the shaft once you have the cases split
 
I don’t know the entire back story, but I wasn’t aware you need to split cases, just to change out a clutch basket?

I thought you can remove the basket if you pull the inner spacer and bearing after removing the inner nut (with an impact like suggested)?  But I’m about 1100 miles from my FSM.

Later, Doug
1978 z1000 Streetfighter
1976 z900 ‘Stripfighter
1978 z1000 w/RC Turbo
1979 z650 Resto-Mod
1983 Gpz750 Resto-Mod
2018 Z900RS
Last edit: 08 Jun 2026 21:32 by StreetfighterKz.

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  • zed1015
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Re: 77z1000 complete clutch replacement

08 Jun 2026 23:20
#924728
how do you go about removing the clutch basket from the shaft once you have the cases split

 
I don’t know the entire back story, but I wasn’t aware you need to split cases, just to change out a clutch basket?

I thought you can remove the basket if you pull the inner spacer and bearing after removing the inner nut (with an impact like suggested)?  But I’m about 1100 miles from my FSM.

Later, Doug
On the earlier kickstart engines you can only remove the plates and inner hub without splitting the cases.
It's only the later J/GPZ ty[e engines that the whole basket can be removed through the outer cover.
AIR CORRECTOR JETS FOR VM CARBS AND ETHANOL RESISTANT VITON CHOKE PLUNGER SEAL REPLACMENT FOR ALL CLASSIC AND MODERN MOTORCYCLE CARBURETTORS
www.kzrider.com/forum/23-for-sale/611992...lide-mikunis?start=1






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  • zed1015
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Re: 77z1000 complete clutch replacement

08 Jun 2026 23:25
#924729
So I have decided to replace my chatterbox of a clutch with a new APE Track king clutch including a rebuilt clutch basket heavy duty extra plate clutch kit with needle bearing never seize clutch pusher my question is how do you go about removing the clutch basket from the shaft once you have the cases split I can’t find this process in the workshop manual are there any videos out there showing this procedure
tia for any assistance 
It's easier if you remove the plates, centre nut and inner hub before splitting the cases then once the bottom case is off you just lift out the input shaft and slide off the basket.
AIR CORRECTOR JETS FOR VM CARBS AND ETHANOL RESISTANT VITON CHOKE PLUNGER SEAL REPLACMENT FOR ALL CLASSIC AND MODERN MOTORCYCLE CARBURETTORS
www.kzrider.com/forum/23-for-sale/611992...lide-mikunis?start=1






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  • Wookie58
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Re: 77z1000 complete clutch replacement

09 Jun 2026 01:21
#924733
I used one of these on my "J" motor. With it in gear and a piece of tube over the handle I was able to torque up the clutch, generator rotor and gearbox sprocket by holding the trans with this.

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