Gen 1: 2004-2005 Need some help installing a new clutch - Kawasaki
LinkBack Thread Tools Display Modes
post #1 of 3 Old 05-17-2012, 02:51 PM Thread Starter
Track Day Rider
sksksks's Avatar
Join Date: Jul 2010
Location: California
Posts: 148
Posting Frequency
Need some help installing a new clutch

My clutch went out and my rod broke and so I went ahead and ordered an entire assembly from ebay for a good price. Now, I've run into an issue, or maybe that's just how its supposed to be? I'm not sure so I'm looking for some guidance.

Pretty much, the new clutch rod that I have will not go in its hole all the way like my old broken one will. this won't allow my clutch hub to be put on so it's flush and snap right into place. What can I do? Am I supposed to take a hammer and jam that sucker in some more? seems like I shouldn't have to?
sksksks is offline  
Sponsored Links
post #2 of 3 Old 05-17-2012, 03:46 PM
REPOST Enforcement Mod
SkyDork's Avatar
Join Date: Feb 2006
Location: Wesley Chapel, FL
Posts: 13,540
Posting Frequency
If you have to take a hammer to anything, there's something wrong! The first thing you need to do is verify you got the right part off eBay. There's nothing that holds the pusher rod in besides the outer hub. It's a slip fit in there and retained by the spring plate itself. Make sure you have the tabs in the spring plate aligned properly with tabs on the the inner hub. It goes on a specific way.

I may not be perfect, but at least I don't ride a Suzuki.

Ridding the Internet of bad grammar, 1 post at a time.

SkyDork is offline  
post #3 of 3 Old 05-17-2012, 04:32 PM Thread Starter
Track Day Rider
sksksks's Avatar
Join Date: Jul 2010
Location: California
Posts: 148
Posting Frequency
Hey so here is the part that is the issue. Ebay sent me a whole clutch assembly, all the parts seem to be fine. I am trying to compare to my original one. Aside from the top end being thicker (which I assume my original one has just been grinded off as you can see a lot of wear) I can't really tell a difference.
with the original one on, my hub plate will snap on and sit in place. but with the new one, because of it not going in all the way, it wont stay flush and has a wobble to it... i can put the springs on and everything looks okay after but this wobble before I put the springs on does not seem okay to me. so, its either they sent me the wrong rod or thats just how its supposed to be?? how can I know? Lol I mean my original did break so that must mean that it was effed up?
sksksks is offline  
Sponsored Links

Quick Reply

Register Now

In order to be able to post messages on the Kawasaki forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Similar Threads
Thread Thread Starter Forum Replies Last Post
Gen 4: Help re-installing clutch cable please? Lumiera The ZX-10R 1 05-11-2012 07:12 AM
Gen 3: Help installing clutch cable JesseN13 The ZX-10R 1 04-30-2012 03:03 PM
Installing Clutch Today, ANY TIPS? pablovelez Performance and Tech 18 07-09-2007 11:15 PM
Installing 520 kit, how to sumjoeguy Performance and Tech 4 06-05-2006 04:19 PM
need help installing 16t zexxx04 Performance and Tech 12 01-03-2005 11:28 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome