Clutch problem again... 03 ZX636

[Kuro]

I've asked this over at the Kawi forums too

With the bike off and in 1st gear, I pull in the clutch and try to move the bike but there is a significant amount of resistance. It seems like the clutch is not disengaging. So much so that if I try sitting on the bike and duck walking backwards, its at the point where I can barely move it backwards on flat ground and impossible to back up a small incline.


The weird part is that when I tried testing the new install, it felt like the clutch was slipping because when I accelerated, the revs would go up more than it would normally and the speed increased quite slowly.


Things to note:
-All plates are new (both steel and fibre - should be no warping)
-Fibre plates were soaked in oil for 24 hours prior to install
-Tried adjusting the cable at the perch and at the cover in all combinations
-The last fibre plate that was installed went into the fingers of the basket (I've read that some people do this on the last TWO fibres)
-I've inspected the cable for fraying or being snapped.... I can't see anything broken.




Possible problems:
- I read about a bushing falling out of the push rod falling out into the slave cylinder?? (sounds like a hydraulic clutch post... mines cabled) - I also didn't see anything falling out.
- Also read about torque springs installed in wrong direction ?? - no idea.


Any ideas?
Thanks

 

[frekeyguy]

Where r u located ? Maybe we can just rebuild the whole thing and go over everything in detail

 

[Kuro]

I located in Scarborough

 

[djltoronto]

I've asked this over at the Kawi forums too

With the bike off and in 1st gear, I pull in the clutch and try to move the bike but there is a significant amount of resistance. It seems like the clutch is not disengaging. So much so that if I try sitting on the bike and duck walking backwards, its at the point where I can barely move it backwards on flat ground and impossible to back up a small incline.

What you described here is the normal operation. With the bike off, in gear, pushing the bike should be difficult.



The clutch slipping part is another issue. Are you 100% positive it's not simply a cable adjustment issue?

 

[Kuro]

Well on my CBR1K, I can clutch in and quite easily push or pull it around in 1st. This 636 is really hard ... and its lighter too.

I've adjusted the cable at the cover all the way up and all the way down just incase I somehow got it wrong. At each setting, I also dialed the adjustment knob all the way in and out too. Could it be that the cable is just too stretched out?

I measured the stack and its about 38mm. (although with a measuring tape..)
Tolerance is for clutch plate assembly length 37.7 ∼ 38.3 mm

What you described here is the normal operation. With the bike off, in gear, pushing the bike should be difficult.

The clutch slipping part is another issue. Are you 100% positive it's not simply a cable adjustment issue?