New Member - Clutch Help 1983 KZ550 - :-)

[ENR_Kyle]

Hi.. I am new to the fourms.. Glad to be here..


Heres my story and problem...

When I turned 17 I bought a 83 KZ550.. I drove it for a few months until I lost my license.. I still drove it in a feild by my house without a license.. When doing this I broke the clutch cable. So I put it away and focused all my attention on my 99 Grand Prix GTP and school.. I am now a trained mechanic. I went to school for 2 years and I completly understand cars... Here I am 21 years old and gas is $3.40 a gallon.. So I decided to get the bike out.. I got my license back when I was 19 and I will NEVER lose it again (its horrible).. SO now I am ready to get it back out and on the road.

when on got it out I replaced the clutch cable.. but there was a problem. I got the cable on all hooked up right but when you pull the cluch it goes tight.. I went over it many times.. I get how it works. you pull it and it in turn pushes a rod that goes into the engine.. Well that rod going into the engine will not move.. what exacly is behind that rod?.. do I need to completly remove the engine to fix this?..

Thanks.. I will add more details as I get them.

[elr658]

Access the release mechanism and put it in correct position.

The other end of the pushrod is accessed by removing the clutch cover.

[ENR_Kyle]

ohh cool. I think thats what I wanted to hear.. Basicly, drain the oil, then I can pully the cover on the lowe end of the engine on the right side (opposite side as the clutch pushrod) and I will most likely see the rod not pushing and arm that it should be?..

Thanks for the quick response..

[ENR_Kyle]

I just came across a manual for my bike.. its scanned.. but I can read it:

"Chapter Five CLUTCH"
All of the clutch components can be
removed while the engine is mounted in the
frame."

"5. Remove the bolts, springs and the pressure
plate.
6. Remove the pressure plate pusher and the
steel ball behind it.
7. Pull the clutch release pushrod out of the
center of the transmission input shaft.
8. Remove the clutch plates from the hub.
9. Remove the clutch hub nut from the input
shaft (Figure 12)."

[ENR_Kyle]

sorry to keep posting.. just another quick question..I just pulled the drain plug so it will be dry for me to work on tommorow.. Is that ok.. It wont dry out the clutch plates will it?.. Thanks

[StarGate]

No problem as long as you don't turn the engine over.

[ENR_Kyle]

awsome.. Thanks.. Im on my way out to the garage now to work on her,

[ENR_Kyle]

OK.. I got the clutch working like a charm.. BUT.. I lost my key

so I had to break the lock out.. and turn it with a scredriver..

then as I was driving the part that turns poped out on my and the little plastic thing got pushed down the the spring and it locked my handle bars to the side when I was turning.. then i fell.. nothing major.. bent the bars, got a little cut.. I was only going like 10..

so lesson learned the hard way..but.. I will now break the plastic thing off. put the metal thing back in and weld somehting to it so I can just turn it on or off.. then I will put a secret switch that needs to be on to let it run so it wont get stolen..

long story short.. clutch is fixed