RobertMcBeth
Novice Class
Posts: 47
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posted June 02, 2016 09:27 AM
 Edited By: RobertMcBeth on 2 Jun 2016 10:29
zx12 muzzy clutch kit install PROBLEMS
Had some clutch chatter in my 02 z12r
bought muzzy kit from schnitz racing
pulled old clutch, was an aftermarket kit, found a broken first skinny clutch
Installed muzzy clutch kit,
Did Not Install last fiber offset
Removed all but one chatter ring (literally one cone shaped ring, cone facing out inside the firts skinny clutch ring)
Sprayed and Wiped steels with brake clean before installation
Intstalled Steels sharp side facing out
Lubed fibers with oil
Did all this per information i found on here per old post by DOUG MEYER
Adjusted clutch cable per instructions, 1/4 gap at lever adjustment, loosened nuts on adjustment at cover, pulled clutch cable tight, tightened adjustment at clutch cover and adjusted clutch freeplay at clutch lever.
At first I had disengagement issues, had to tighten the cable so tight there was no freeplay and there was actually tension on the cable, to keep it from lunging forward and driving through the clutch when shifted out of neutral into first gear
Pulled everything apart and re-installed verifying I had installed everything correctly.
Freeplay is now satisfactory
Have done this 4 times now and cannot get satisfaction
Bike runs and shifts smooth now, for the most part, still having disengagement issues intermittently.
Bike Seems to have lost power as well, and refuses to light up the rear tire when a burnout is attempted, just drives through the brake, or barely turns the rear tire.
I AM SO FREAKING FRUSTRATED RIGHT NOW I WANNA LIGHT A MATCH AND GET A CAN OF GAS
bueller?
HELP!!!!!!!
  
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dougmeyer
Needs a job
moderated
Posts: 2713
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posted June 02, 2016 02:44 PM
Edited By: fish_antlers on 2 Jun 2016 17:47
It sounds like you did do everything right and there were literally thousands of these kits sold and operated trouble free. I suggest you look at the puller and actuator shaft for damage. There should be no apparent wear on these parts. The puller rotates on a ball bearing and there should be no relative motion between the puller and actuator shaft. If you take the parts out and send me some pictures I'll be glad to look at 'em
dmeyer (at) bendcable.com
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It's not that I think you're dumb, it's just that so much of what you know isn't true....
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fish_antlers
Administrator
The Truth is Out There
Posts: 21893
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posted June 02, 2016 07:14 PM
awesome offer of help Doug 
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What business is it of yours where I'm from, Friendo?
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RobertMcBeth
Novice Class
Posts: 47
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posted June 07, 2016 08:05 PM
Edited By: RobertMcBeth on 7 Jun 2016 21:30
quote:
It sounds like you did do everything right and there were literally thousands of these kits sold and operated trouble free. I suggest you look at the puller and actuator shaft for damage. There should be no apparent wear on these parts. The puller rotates on a ball bearing and there should be no relative motion between the puller and actuator shaft. If you take the parts out and send me some pictures I'll be glad to look at 'em
dmeyer (at) bendcable.com
Doug, thank you for your time and insight.
I thought the same thing as you, both the puller and actuactor, infact did have some wear.
I replaced these parts tonight. I also installed a new clutch cable, added the missing spacer on the actuator at the clutch cover, replaced spacer on the puller, would have replaced bearing at puller as well but the girl at my local kawi dealer ordered the wrong bearing (even though i gave here the corect part #) and when I arrived to pick up my parts today she had the bearing for the basket. I also went ahead and replaced the last fiber and first fiber on the clutch pack because they had darkened in color.
No noticeable difference, same problems.
I tried an experiment over the weekend. I borrowed a friends dial caliper, though it does not read in decimals, the stack measured just over 56mm. I replaced 2 2.0 steels, with a single 1.6 and double 1.6 steel bringing the stack height up to just under 58mm.
This made it easy to once again light the tires effortlessly.
Thinking the same as you, tonight I reinstalled the full muzzy kit as sold, thinking the shaft and actuator were the problems, and my stack height was potentially too high and i shouldnt have to add extra shims to it.
Im going to take a break on this lil headache of a project until friday when i recieve my correct bearing for the puller. Will also purchase 2 1.4 steels and a harbor freight digital dial caliper, just incase my only recourse is to shim the stack height up.
The only other thing i can think is that the hd schnitz racing springs I purchased are absolute garbage. I have noticed when i pull everything apart the are "bound" in the pressure plate and require some effort to pull out.
I will keep you gentlemen posted.
Thanks again, I swear, a gallon of gas and a match look mighty apealing at this moment, as I am at my wits end.
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frEEk
Administrator
ummm... yeah
Posts: 9660
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posted June 08, 2016 08:37 PM
Now this is good ol' fashioned zx12rzone content. Love it.
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RobertMcBeth
Novice Class
Posts: 47
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posted March 31, 2018 08:23 PM
Just reading some old post, stack height was off as sold, used some different thickness steels in the end of the pack and all works fine now
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TurboBlew
Moderator
BUSY DOING THE SCHIAVO
Posts: 4590
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posted April 10, 2018 03:08 PM
um asking about a zx12 Muzzy clutch kit in 2016??? WTF? Dude that ship sailed in 2005.
too funny! FYI... honda nighthawk fibers fit! 
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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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RobertMcBeth
Novice Class
Posts: 47
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posted May 05, 2018 08:29 AM
Yeah, man kinda hard to find info on such an old bike, harder to find parts sometimes
I love my ole girl no need to be condescending, turboblew
Any advantage to nighthawk fibers?
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