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Author Topic: Clutch Not Disengaging.  (Read 669 times)

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Gowron

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Clutch Not Disengaging.
« on: September 21, 2012, 09:08:58 PM »

So I have a issue with the rebuild I am working on. Today I got the chain put on the bike and attempted to get the bike rolling as I already have everything else pretty well set.

When I pull on the clutch and shift it into gear you can tell that there is nothing that the clutch is doing. It basically seems as though the clutch isn't grabbing anything. I have taken and adjusted the clutch pin adjustment. Both making it as tight as I can and having it till it is just barely touching the pin. Every time I try to shift into gear it just grabs. Nothing seems to be happening with the clutch in the "active" position.

Thoughts?
« Last Edit: September 23, 2012, 11:59:01 AM by Gowron »
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Chicagoland IL
1978 KZ 650 B? D1? Still working on that one...

rstnick

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Re: Clutch Not Grabbing But not slipping
« Reply #1 on: September 21, 2012, 09:25:13 PM »

I'm not really understanding your question.
Do you feel the spring pressure when you pull the clutch lever in?

The engine needs to be turning/running to shift through the gears.
Rolling the bike forward will allow you to shift through the gears.

With the bike stopped, you don't feel much while pulling in the clutch lever, short of the clutch springs pressure.

Make sure all 4 sprocket cover mounting bolts are in and tight, or the sprocket cover will move when you pull in the clutch lever, and it wont work properly.

Adjust the clutch mechanism on the sprocket cover as per a manual:







« Last Edit: September 21, 2012, 09:26:52 PM by rstnick »
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Rob

KZ650.info home page with tech tips, manual downloads, how tos, etc: http://kz650.info/

'77 C1 project - newest
'78 C2 Candy Apple Blue, 105 000 kms, 18" wheels front & back, Rickman fairing, Koni shocks, Progressive springs, braced stock swingarm, GSXR600 rear sets, ATK fork brace, SS brake lines, Kerker exhaust, K&N filter in air box, ported, 1st over bore, Kawi electronic ignition, bought in '84.
'78 C2 project 6 #s off other C2
'79 C3 frame with title & bits, was my brother's.

Gowron

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Re: Clutch Not Grabbing But not slipping
« Reply #2 on: September 21, 2012, 09:53:11 PM »

Ok. So I think I know whats wrong. And I think someone before me put the wrong part in the clutch cover (had two that came with the bike and chose the one that looked better). The one that isn't installed on the bike right now moves further when the clutch lever is pulled and I am wondering if this might be the issue. I probably won't get a chance to test this before sunday. But we shall see.

The engine is running when I am testing this.

I feel the spring when I pull on the clutch.

I did adjust it as per the manual. I have Clymer's book on the 650.

Basically its as though I am shifting into gears without the clutch at all. However I feel plenty of spring from pulling the clutch lever.
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Chicagoland IL
1978 KZ 650 B? D1? Still working on that one...

Seymore

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Re: Clutch Not Grabbing But not slipping
« Reply #3 on: September 21, 2012, 11:09:54 PM »

How much play in the clutch cable?
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Chris -- Been enjoying that free-2-wheelin'-feelin' since 1983...

79' KZ650-D2 [fsm]
(Max)
83' KZ750-F1 LTD [clymers] (Kay)
78' KZ650-B2a (J&H, A Project)
82' KZ1100-A1 Specter (another project)
80' KZ750-LTD (parts supplier...)
77' KZ650-B (parts supplier...)
80' KZ550-A (sold)
80' KZ1000ST (never shoulda sold her...)
77' KZ900Z1 (scarey friggin' fast...)
80' XS650 (first luv...)
.

Gowron

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Re: Clutch Not Grabbing But not slipping
« Reply #4 on: September 22, 2012, 07:46:00 AM »

I've had it to where there is no play and there is only about 1/16" of play.
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Chicagoland IL
1978 KZ 650 B? D1? Still working on that one...

Seymore

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Re: Clutch Not Grabbing But not slipping
« Reply #5 on: September 22, 2012, 01:23:08 PM »

OK. Well, I asked because I had a similar issue. It would go from totally disengaged to engaged almost instantly. A proper adjustment fixed the problem for me. I believe I also had the clutch push rod, under the sprocket cover, misaligned and the cover did not fit properly. I would suggest pulling the cover (again?) and confirm everthing is installed properly there. May also want to disassemble and grease the inner clutch release (mounted to the sprocket cover) and confirm everything is good there.
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Chris -- Been enjoying that free-2-wheelin'-feelin' since 1983...

79' KZ650-D2 [fsm]
(Max)
83' KZ750-F1 LTD [clymers] (Kay)
78' KZ650-B2a (J&H, A Project)
82' KZ1100-A1 Specter (another project)
80' KZ750-LTD (parts supplier...)
77' KZ650-B (parts supplier...)
80' KZ550-A (sold)
80' KZ1000ST (never shoulda sold her...)
77' KZ900Z1 (scarey friggin' fast...)
80' XS650 (first luv...)
.

Gowron

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Re: Clutch Not Grabbing But not slipping
« Reply #6 on: September 23, 2012, 11:54:20 AM »

May also want to disassemble and grease the inner clutch release (mounted to the sprocket cover) and confirm everything is good there.

What exactly would I be looking for and what should I grease for the sprocket cover or behind the sprocket cover?
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Chicagoland IL
1978 KZ 650 B? D1? Still working on that one...

Seymore

  • Geeky photo rider in WA...
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Re: Clutch Not Disengaging.
« Reply #7 on: September 23, 2012, 01:43:44 PM »

The clutch release is all the needs to be lubed under the sprocket cover. Just watch that it throws out properly in the twist and doesn't have any restrictions. Also good to clean up while your in there. Watch for your neutral cable... don't need to damage this aspect.
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Chris -- Been enjoying that free-2-wheelin'-feelin' since 1983...

79' KZ650-D2 [fsm]
(Max)
83' KZ750-F1 LTD [clymers] (Kay)
78' KZ650-B2a (J&H, A Project)
82' KZ1100-A1 Specter (another project)
80' KZ750-LTD (parts supplier...)
77' KZ650-B (parts supplier...)
80' KZ550-A (sold)
80' KZ1000ST (never shoulda sold her...)
77' KZ900Z1 (scarey friggin' fast...)
80' XS650 (first luv...)
.

Gowron

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Re: Clutch Not Disengaging.
« Reply #8 on: September 23, 2012, 04:32:15 PM »

So What exactly do I have to take off to get to this? The only cable I can see once I take the cover off where the push pin goes in is the clutch cable.

The sprocket area is clean as this bike hasn't seen any road time since I've been rebuilding it. Am I going to have to pull the transmission cover off to get at the clutch release?

Any photos of what I am looking for? All I have are a drive shaft, push pin and shifter post in this area.
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Chicagoland IL
1978 KZ 650 B? D1? Still working on that one...

Gowron

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Re: Clutch Not Disengaging.
« Reply #9 on: September 23, 2012, 04:37:11 PM »

Is is possible that since it sat with the clutch open and exposed to the air for several years that the clutch plates are stuck together with the friction plates?

What about the ball bearing? Could that have fallen out if the release pin was removed? Should I look for that?
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Chicagoland IL
1978 KZ 650 B? D1? Still working on that one...

rstnick

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Re: Clutch Not Disengaging.
« Reply #10 on: September 23, 2012, 07:19:53 PM »

The clutch mechanism/release is attached to the backside of the sprocket cover.
The cable goes to it, and as you pull the clutch lever in, you can see the clutch mech. rotate and push outwards, normally pushing against the clutch push rod.
Don't think the ball call come out of the left side of the engine with the push rod/release pin removed.

Do you have a service manual for your bike?
If not, get one soon.
Factory Service Manuals (FSM) are best.
Clymers' manuals are good too for some things.

There are downloadable manuals on site here, and elsewhere too....
http://forums.kz650.info/index.php?topic=1833.0


Quote
it sat with the clutch open and exposed to the air for several years

I'd be taking them off and checking them, see if they're stuck, clean and lube them if useable.
« Last Edit: September 23, 2012, 07:29:20 PM by rstnick »
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Rob

KZ650.info home page with tech tips, manual downloads, how tos, etc: http://kz650.info/

'77 C1 project - newest
'78 C2 Candy Apple Blue, 105 000 kms, 18" wheels front & back, Rickman fairing, Koni shocks, Progressive springs, braced stock swingarm, GSXR600 rear sets, ATK fork brace, SS brake lines, Kerker exhaust, K&N filter in air box, ported, 1st over bore, Kawi electronic ignition, bought in '84.
'78 C2 project 6 #s off other C2
'79 C3 frame with title & bits, was my brother's.

Gowron

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Re: Clutch Not Disengaging.
« Reply #11 on: September 23, 2012, 08:34:38 PM »

Took the clutch assembly apart. Plates were all stuck together. Took them all off cleaned and put back together. Clutch works great now.

Put the first .8 miles on the bike tonight. (Not going any further without plates  :P)
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Chicagoland IL
1978 KZ 650 B? D1? Still working on that one...

rstnick

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Re: Clutch Not Disengaging.
« Reply #12 on: September 24, 2012, 10:06:53 PM »

Good to hear you found the problem.
 8)
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Rob

KZ650.info home page with tech tips, manual downloads, how tos, etc: http://kz650.info/

'77 C1 project - newest
'78 C2 Candy Apple Blue, 105 000 kms, 18" wheels front & back, Rickman fairing, Koni shocks, Progressive springs, braced stock swingarm, GSXR600 rear sets, ATK fork brace, SS brake lines, Kerker exhaust, K&N filter in air box, ported, 1st over bore, Kawi electronic ignition, bought in '84.
'78 C2 project 6 #s off other C2
'79 C3 frame with title & bits, was my brother's.

Seymore

  • Geeky photo rider in WA...
  • KZ650 Oracle
  • ******
  • Offline Offline
  • Posts: 6503
  • I think, therefore I am, I think...
Re: Clutch Not Disengaging.
« Reply #13 on: September 24, 2012, 11:10:46 PM »

Sweeeeeeeet! Glad to hear you got the problem fixed...
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Chris -- Been enjoying that free-2-wheelin'-feelin' since 1983...

79' KZ650-D2 [fsm]
(Max)
83' KZ750-F1 LTD [clymers] (Kay)
78' KZ650-B2a (J&H, A Project)
82' KZ1100-A1 Specter (another project)
80' KZ750-LTD (parts supplier...)
77' KZ650-B (parts supplier...)
80' KZ550-A (sold)
80' KZ1000ST (never shoulda sold her...)
77' KZ900Z1 (scarey friggin' fast...)
80' XS650 (first luv...)
.
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