Clutch not working on KZ900

Bama704

Been Around the Block
Hey ya'll,

My clutch is not working at all. The last time I rode the bike, a few weeks ago, I had no issues at all nor have I ever had any problems like this. Last year I replaced the clutch plates, friction plates, and springs. My oil is right where it should be in the sight window and it is filled with Rotella T 15w-40. I have adjusted all three points for the clutch adjustment (at clutch lever, on the wire between the pipes, and at the push rod) with no change. If I hold in the clutch and try and roll the bike in first gear it does not engage and the wheel will not spin. Anybody have this happen before? I'm at a loss on what to do.
 

hillsy

Over 1,000 Posts
Is the bike running when you are trying to engage the clutch? If the bike is cold and hasn't been started for a while the clutch plates will be "stuck" together with cold oil.


Otherwise, maybe re-check the worm gear hasn't broken.
 

Bama704

Been Around the Block
I have tried on a cold motor as well as warming up the bike to see if I can get the clutch plates to break free. No luck so far.

Where is my worm gear and what is it?
 

hillsy

Over 1,000 Posts
It's the clutch pushrod actuator behind the front sprocket cover. There is a worm gear inside it which may be playing up / incorrectly adjusted.
 

cxman

Over 1,000 Posts
DTT SUPPORTER
best thing to do is pm me and sell it to me

i will worry about then
 

Bama704

Been Around the Block
I should have thought about selling it!! :D

I will take a look at the worm gear when I get some time.
 

2_DONE_THE_TON

Over 1,000 Posts
DTT BOTM WINNER
The clutch mechanism is normally "relatively" unsensitive to maldjustment...even when maladjusted my XS 750 clutch will engage but when ridden will slip.
Make sure that you got the assembly right...
On my XS 750 there is a tiny steel ball between the worm gear and the pushrod which can be easily lost...It sounds like your worm gear isnt touching your pushrod.
Can you check from looking in from above if your pushrod is pushed "into" the motor?

cheers
 

semmins

Been Around the Block
DTT BOTM WINNER
If the clutch was working ok a few weeks ago, and hasn't been touched since then, I would agree with hillsy when he said the plates are stuck.
I've had similar issues on a few bikes. Just put the bike on the centre stand, start it up (keeping the clutch lever pulled in), and put it in gear. Rev it to 5/6 rpms, and literally stand on the rear brake. It might take a few attempts, but it's worked for me in the past.
 

julian.allard66

Been Around the Block
Sounds like the clutch is failing to disengage, if you've fitted EBC clutch plates this isn't unusual, rock the bike backwards and forwards with it in gesr until you feel ghe clutvh free off, the way to avoid it in future is to ride the bike more often.
If the clutch is slipping, you've either put it together wrong or adjusted it wrong, the worm drive on KZs is weird to adjust read the manual carefully.
If you've no drive at all the clutch centre nut or sprocket nut has probably come undone.

Sent from my SM-T560 using Tapatalk
 

Bama704

Been Around the Block
Thanks for all the suggestions, I was able to get it to work this morning. The clutch plates were stuck together. I put it on my paddock stand and let it warm up then engaged first great at 3500rpms. I could hear the clutch plates come free and am now able to use the clutch as normal.
 

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