1rhed12
Parking Attendant
Posts: 7
|
posted August 10, 2009 03:04 PM
No tension in clutch cable
Hey guys, new to this forum and found limited info for my dilema.
02 zx12.....36k...mostly commute...some high speed runs...buzz thru twisties...
I exploded my clutch basket and recently put it all back together, only to find that the cable doesn't seem to have enough adjustment to give tension. I am literally at the very end of the
lever and cover adjustments just to get the actuator to pull the clutch rod.
I bought OEM fibers and reused the stock steels. I've taken it apart twice to ensure everything went back correctly. Stack height appears to be correct...comes right out to the pressure plate....Still no tension.
I'm pretty sure the actuator is connected properly, but not sure if it is worn or if cable has stretched...although it was ok prior to basket exploding...actuator seemed ok too.
Any suggestions?
Have I overlooked the obvious?....
first time changing basket...second time for fibers.
I'm no pro and will gladly accept advise.
Thanks
  
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted August 10, 2009 03:31 PM
 Edited By: KZScott on 10 Aug 2009 23:32
measure the clutch pack. it sounds too tall. are you using a gasket? is the pressure plate in correctly? it only really fits one way.
pics?
how many steels and fibers? are you using 1.6s or 2.0s?
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
1rhed12
Parking Attendant
Posts: 7
|
posted August 10, 2009 04:36 PM
For the fibers, I bought as listed from the dealer, 12 total(9,2,1)....
I reused the steels(including thin springs and washers) and put them back in the exact same order they came out. Not sure of the # and gauge of steels..but it is the bone stock set up for 02.
Yes, I am using a gasket.
I am not absolutely sure that the pressure plate is on as per the diagrams you posted...
eventhouh I have the same manual and overlooked those alignment marks(dummy me).
And I will take it back apart and measure the stack...
Thanks for your time and patience Scott, I've seen you kinda keep answering these clutch questions over and over...even in the other Kaw forum...we'll get a clue soon 
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted August 10, 2009 05:27 PM
post back when you get the measurement of the stack height, also get pics if you can of these pieces, or check to see if they are ok
those above are ok
rounded corners are bad:
burned thru is also bad:
yes ive been there and broke that lol
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
1rhed12
Parking Attendant
Posts: 7
|
posted August 10, 2009 06:38 PM
Ok...I'll get the stack height and post pics of clutch pull rod and actuator tomorrow. I saw those pics above last night duing a search in this forum...
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted August 11, 2009 05:15 AM
probly from when i was just learning this stuff 
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
1rhed12
Parking Attendant
Posts: 7
|
posted August 11, 2009 06:02 PM
Edited By: 1rhed12 on 12 Aug 2009 03:07
Stack height is 57.15mm....12 friction...11 steels....also the 2 thin springs, 2 thin washers.
pressue plate was installed correctly....
See pics of actuator and clutch rod below......
Also, bike is 02...I believe the basket I replaced it with is an 00-01...would this create any issues with the 02 hub?
I was able to get a better bite on the clutch rod without the spring on actuator and also when I applied downward pressure with spring...does the actuator look like it needs to be replaced?
[img]http://s982.photobucket.com/albums/ae309/sqid499/[img
[IMG]http://i982.photobucket.com/albums/ae309/sqid499/015.jpg[/IMG
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted August 11, 2009 07:23 PM
the actuator(green) looks a little worn, but not really bad. a new one will give you a little more adjustment, but not much. do you have the bearing and washer for the pusher rod? (black) if one is missing it will make the stack height seem way high. in the first pic i posted, you can see both on the pusher (black)
what sort of angle are you getting on the actuator? it should be around 60 degrees(page 4 section 5)
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
1rhed12
Parking Attendant
Posts: 7
|
posted August 12, 2009 12:30 PM
Yes, I have the bearing and washer for the pusher, but still not enough to pull stack with lever.
The actuator seems to grab at the correct angle...I feel the tension...then slips and grabs again with less tension.
Could it be that the actuator is worn enough that is does not grab the puller properly?
If so, it may explain why I can't get any adjustment.... and clutch lever has no tension...?
might even explain why basket exploded to begin with....not sure...maybe I'm reaching with that idea...
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted August 12, 2009 01:34 PM
it allmost sounds like its popping sideways out of place if it grabs at the correct angle, then slips and has less tension. how is the fit of the rod into the trans shaft? much side to side play? what about the bearings in the cover for the actuator? the 2 dowel pins are holding the cover in the correct place too right?
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
1rhed12
Parking Attendant
Posts: 7
|
posted August 13, 2009 04:01 PM
The rod fits into the trans shaft without much play.
The 2 dowel pins are in place.
The bearings in the cover appear to be ok..they came with the cover when bought used...
but for argument sake, I'll take the ones from my cover and replace them...
I ordered a new actuator and spring yesterday....everything else that you have suggested or
commented on,seems to be as it should...
Hopefully the actuator is worn enough that it wasn't locking on...
I'll update once part arrives and installed.
Thanks for hanging and helping to get my problem resolved.
|
1rhed12
Parking Attendant
Posts: 7
|
posted August 20, 2009 08:14 AM
Well...I ordered the actuator....I installed it... put cover on..and I'm not sure if the old one was worn and would'nt attach properly....but the new one seems to...works now!!
I'm not sure if I was just never getting the correct angle...anyway...on the road again.
I contemplated trying to attach correctly with old actuator....naaa...leaving good enough alone ...don't want to open again until fibers wear down.
KZScott...thanks for hanging and educating...you were defintely instrumental in the resolution of my problem....I appreciate your help.
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted August 20, 2009 02:51 PM
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
ceeza
Parking Attendant
kawasaki
Posts: 14
|
posted September 13, 2009 09:19 AM
kz scot i got my stack correct and still im have major clutch it seems like this is been all sunner i put new parts in and same shit it is very upsetting to get to the track line up and nothing happens im runnin10 steels and 11 fibers with no small spacer in back of clutch lockup muzzy aftermarket basket and hub and nothing happens to go right help................................................................................
____________
kz started it all for me
|
KZScott
Needs a life
high on speed
Posts: 7235
|
posted September 13, 2009 10:02 AM
can you be more specific of what issue you are having please?
stack height will need to be different for a lock up anyway in my expirience. i dont measure stack height anymore now that i have an MTC lock up. i just play with stack height in order to get the correct clearance between the pressure plate and the arms on the snowflake. i dont actually measure the total any more, i just make sure the clearance is ok, and the angle on the puller is correct.
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
|
|
|
HOME
NEW TOPIC