EastBayDave
Needs a job
Posts: 2245
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posted June 14, 2004 05:54 AM
rough shifting after Muzzy Clutch & C. Basket
Man the clutch sure works nice now (engagement), but...
It shifts like chit! Going into first is now....karunch! It's friggin' loud as hell; sounds like somethings wrong?
Not only that, but I must be much more deliberate now when shifting...it seemed to "stiffen up" after the clutch/basket installation. Numerous adjustments don't seem to help...
Is this the same everyone else experience? Or do I have something wrong?
____________
Enjoy the ride!
02' ZRX1200
00' ZX12R sold
  
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wannabe
Pro
Posts: 1931
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posted June 14, 2004 11:46 AM
Did you readjust your clutch cable freeplay after you did the swap?
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ZXLNT
Needs a job
Kawpuke Extraordinare
Posts: 2853
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posted June 14, 2004 12:07 PM
It's dragging, need adjust it a little more to get it to disengage completely...
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cowboy
Pro
Posts: 1061
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posted June 14, 2004 12:24 PM
cable adjustment or stack height is my guess.I've had the same problem and installed 2 1.6mm steels in the place of 1 2mm steel to increase the stack height a bit.
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deathpulse
Pro
Posts: 1688
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posted June 14, 2004 01:11 PM
dave - its prolly cable adjustment. Mine is so smooth that I thought I did something wrong at first  . No clunkning or anything, just silky smooth shifting - at first I thought that mine was continually slipping it was so smooth (but the power applies to the ground well).
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TurboBlew
Moderator
BUSY DOING THE SCHIAVO
Posts: 4590
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posted June 14, 2004 06:49 PM
The cable does stretch over time too. Seen this on a few 2000 models.
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psycho1122
Pro
Posts: 1608
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posted June 15, 2004 08:37 AM
The drive Steels are all stamped. Make sure the smooth "rounded" stamped edges are all facing out. This allows smoother disengagement.
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You say PSYCHO like it's a BAD thing!!
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ninja12
Needs a job
Posts: 3310
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posted June 15, 2004 01:35 PM
I like them all facing in. smooth engagement is more important to me.
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EastBayDave
Needs a job
Posts: 2245
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posted June 16, 2004 04:50 AM
Well thinking I did something wrong; I pulled it completely apart & reassembled VERY carefully. Steels look good (no bluing but haven't been to the strip yet.) I lubed the chit out of the (new) cable; & adjusted & adjusted until it felt just right.
Still seems somewhat "stiff" or maybe (?) difficult disengagement. The edges are pointed out, the damn thing is dry as a bone (it appears to have no oil at all), so I soaked overnight the fibers. Still the same thing; no change after complete disassembly & reassembly. Weird; seems to function ok other than the "rough" shifting in the lower gears. Works fine during speed upshifting w/o the clutch....hmmm...
The worst part is putting it in gear -CRUNCH! I'm starting to hold the clutch in at stoplights so I'm not embarrassed every time I toss it into first at a light. All KAW's I've had were always somewhat loud going into first, but man this thing sounds like a shift fork is going to come flying out thru the cases....
____________
Enjoy the ride!
02' ZRX1200
00' ZX12R sold
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ninja12
Needs a job
Posts: 3310
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posted June 16, 2004 04:57 AM
It will go away. I think it's caused by too much oil inthe clutch,
If that makes any sense. New clutches sometime do that.
Kevin Cadby said he sometimes push the bike to get it rolling before
putting it in gear the first time. my .02
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EastBayDave
Needs a job
Posts: 2245
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posted June 17, 2004 04:36 AM
quote:
It will go away. I think it's caused by too much oil inthe clutch,
If that makes any sense. New clutches sometime do that.
Kevin Cadby said he sometimes push the bike to get it rolling before
putting it in gear the first time. my .02
Yeah, I do that too. At a stoplight when it's about to change to green, I give the bike a little shove so it's moving forward slightly as I put it in gear. Sometimes helps, other times doesn't.
I'm stumped....guess I'll just keep riding it for awhile. My warranty runs out TODAY so I'm on my own now...
____________
Enjoy the ride!
02' ZRX1200
00' ZX12R sold
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CrotchRocket
Moderator
Bracket Racing with Betsy
Posts: 8038
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posted June 17, 2004 06:29 AM
Dave, are you sure you installed the Basket onto the gear perfectly???
Are the split gears perfectly lined up???
It was a little tricky getting the basket gear onto the Tranny gear also!!!
Is the Hub nut torqued correctly???
Sorry, but I think you should take it all apart and re-install it...AND, have someone there to give you a hand getting the basket lined up with the tranny gear...
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Jason Miller StreetBike Seminars
*****DragRacers do it better, because they dont cut Corners*****
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ZXLNT
Needs a job
Kawpuke Extraordinare
Posts: 2853
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posted June 17, 2004 06:42 PM
Man I would think it would have ruined the crank gear and or the clutch gear by now if it wasn't aligned correctly. Not much room for slack on that. Either it goes on or it doesn't. No room for halfway on. Also that thing would whine like crazy with misinstalled basket. Take an awl and line up the gears on the basket. Should be a small alignment hole on the back side of the backing plate. Stick the awl down in there and pry the gears until they line up. It should hold its place as you install it....
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dougmeyer
Needs a job
moderated
Posts: 2713
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posted June 17, 2004 09:38 PM
Dave,
None of what you describe is normal with a clutch kit installation. The clunking is caused by the clutch dragging. Recheck everything. You didn't get creative with plate thicknesses/stack height did you? Assuming you used our kit just as we send it, look at the actuator shaft/pull rod and make sure you've got it all aligned properly.
Doug
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EastBayDave
Needs a job
Posts: 2245
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posted June 19, 2004 06:44 AM
 Edited By: EastBayDave on 19 Jun 2004 07:50
Thanks for all the input guys; I really appreciate it.
There's no noise ("groaning" noise the stocker made is gone), & it seems to operate ok, so I inclined to think it's installed correctly. I've already installed it twice to be sure (couldn't remember if that washer w/the text on it was in correctly after the first install, so the first thing I did was pull it out & reinstall very carefully....it was installed correctly the first time.)
Didn't have much trouble w/the basket going on the gears, just used a drift thru the center & lined right up & it "sunk" into home. Snick! I don't think that's the issue.
I think Doug's statement of dragging is correct; it feels an awful lot like the old KZ days & Barnett clutches which would drag if not adjusted right.
I didn't do anything w/stack height, just installed it exactly w/the Muzzy parts per directions. I even kept the little fiber plate & 2 "springs" on the far inside part of the basket. I found it hard to measure stack height with the new basket. Where do you take the measurement when there's no "slots" like the stock basket has?
Probably the problem eh'? I need a smaller steel or two maybe? Again, Thank you all VERY much in advance for all the suggestions; there's no ZX12R riders around here to swap info with sadly...
____________
Enjoy the ride!
02' ZRX1200
00' ZX12R sold
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dougmeyer
Needs a job
moderated
Posts: 2713
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posted June 19, 2004 08:14 AM
Edited By: dougmeyer on 19 Jun 2004 09:15
Dave,
Well there you go. Nowhere are you told to "keep the springs and narrow plate". Take that shit out. Run only the Muzzy supplied clutch parts. The 11 "wide" fibers and the 10 2.0 plates. Don't be concerned with meeting a specific stack height. Your clutch will work perfectly if you use it as we ship it. Too much thinking again!
Doug
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deathpulse
Pro
Posts: 1688
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posted June 19, 2004 09:06 AM
I second Doug's statement - I used the kit and the billet basket exactly as per spec, and she's the sweetest damn clutch I've ever had in a motorcycle. What do you mean by the springs on the far inside of the basket? The only springs I saw were the 6 on the outside of the whole assembly. You swap 3 of the stockers out with the 3 that muzzy's supplies and its all good...
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kangpow
Expert Class
Posts: 144
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posted June 19, 2004 01:13 PM
On the 03 you have two sets of springs in the clutch. Aren't you suppose to use the first one and not the one in the middle ??????
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dougmeyer
Needs a job
moderated
Posts: 2713
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posted June 19, 2004 06:36 PM
Dave is referring to the large "bellville washer" type springs that are in with the narrow fibers. The are called "judder" springs and serve to dampen clutch chatter. Do not use these with your race clutch.
Doug
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TurboBlew
Moderator
BUSY DOING THE SCHIAVO
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posted June 19, 2004 07:01 PM
kang... take all that crap out and throw it in the trash. The mini fibers/spring will break easy if abused!
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Official Charter Member of the RIDERS OF KAWASAKI MEMBERSHIP REVOCATION CLUB
Also a BadAss Internet Forum Moderator 4 Hire!! Come at me brah!
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EastBayDave
Needs a job
Posts: 2245
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posted June 20, 2004 05:00 AM
quote:
Dave is referring to the large "bellville washer" type springs that are in with the narrow fibers. The are called "judder" springs and serve to dampen clutch chatter. Do not use these with your race clutch.
Doug
That's what they are called? Learn something new every day. Thank you Doug!!
I'll pull it again & remove the 2 "judder" springs & the narrow fiber & try it again...
Your right, too much thinking! :P
I really appreciate the help folks... 
____________
Enjoy the ride!
02' ZRX1200
00' ZX12R sold
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