Gen 2: 2006-2007 Gen 2: Clutch problems - Kawasaki ZX-10R.net
 
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post #1 of 9 Old 06-26-2012, 08:45 PM Thread Starter
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Gen 2: Clutch problems

I've been hearing a noise from my bike while holding the clutch in, somewhat like a throwout bearing whine on a car. For this reason I decided to open up my clutch cover and check everything out. I found an awesome how-to thread on here the was pretty much step by step, apparently I messed up somewhere along the way. I pulled my clutches out, they all looked to be in decent shape, I then proceeded to measure each fiber plate to make sure they were within the accepted parameters in the manual. I found that they were all fine and checked out. At this point I started to put everything back together, using the manual's diagram, which had both of the "spring" ring and the flat ring placed behind the second set of plates and fibers. I packed all the rest of the clutches back in, torqued everything to specs, and buttoned it up. I cranked the bike while it was still in the air and the clutch is not engaging, and yes the clutch has been adjusted to both extremes still with no results. The bike has been down for over a month and I was pretty frustrated so I took it to the dealer, where it has been for a week and a half untouched, its a 30 minutes fix which makes that unacceptable. I plan on picking it up and trying to fix it myself. Does anyone know of any common mistakes I could have made?? Any help would be appreciated!
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post #2 of 9 Old 06-26-2012, 09:08 PM
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Stack height too high...Should have a small grove inside the clutch cover..if it looks like more material was grinded away...there u have it...spring ring and flat ring should go in first FYI
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post #3 of 9 Old 06-26-2012, 09:19 PM Thread Starter
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As in the first thing in the entire stack? Before any pressure plates or fibers?
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post #4 of 9 Old 06-26-2012, 09:27 PM
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Sorry had to check parts diagram...spring and flat ring go in after 1st steel in the pack
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post #5 of 9 Old 06-26-2012, 09:35 PM Thread Starter
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That's where I placed it, I also, with the ring facing the correct way. I thought you'd come up with an easy fix for a second! I'm sure its something simple.
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post #6 of 9 Old 06-26-2012, 10:26 PM
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Quote:
Originally Posted by cweeks View Post
That's where I placed it, I also, with the ring facing the correct way. I thought you'd come up with an easy fix for a second! I'm sure its something simple.
is there any firmness on the lever? or does it pull very easy? are you 100% you have that clutch arm (part #13102) installed correct? Just my suggestion...
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post #7 of 9 Old 06-26-2012, 11:43 PM
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Originally Posted by TexasRider View Post
is there any firmness on the lever? or does it pull very easy? are you 100% you have that clutch arm (part #13102) installed correct? Just my suggestion...
This was going to be my question actually.

When you reinstall, you need to take the part that comes out of the clutch cover and rotate it 180* and then push it down and rotate back 180* for it to grab the rod inside. If you did that and still no firmness, the first time I ever did my clutch I screwed up and put the rod that is supposed to pull the clutch apart on the wrong side of the hub you bolt the springs into, the rod should go in first.

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post #8 of 9 Old 06-26-2012, 11:57 PM
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Did put the pushrod in then the pressure plate?
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post #9 of 9 Old 06-27-2012, 09:41 PM Thread Starter
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Op, that's how I installed the clutch arm. Texas, as of now the clutch has the same amount of tension on it prior to pulling the clutch. Not guilty, the order of installation was 1) insert clutch pack 2) insert pushrod 3) Insert outside plate(pressure plat) 4) Torque everything and button it up. Thanks for the info guys!
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