gumbybob
Novice Class
Posts: 73
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posted August 30, 2010 08:26 AM
Clutch lever problem....any suggestions?
I recently installed ASV levers (long clutch/shorty brake) and love the look & feel of them. I have maybe 300-400 miles on the bike since the change-over with no issues at all....until now. Yesterday, I went for a ride with the boys and after 50-60 miles, whenever I gave the bike some gas, the clutch slipped like crazy (say 50MPH in top gear, open her up and it would spin up to 7000-8000rpm). Felt like the back tire was slipping, but it was all clutch slip. The engagement for the clutch was feeling like it was all the way out ( I don't believe there's adjustment for that. There's only adjustment for distance from lever to bar like stock). If I pulled the lever in just a tiny amount, the clutch was disengaged. So I believe it was the lever. I put the stock lever back on and it ran just fine after for the few miles I rode after that..
SO....it seems like the rod in the clutch lever that engages the clutch in the mechanism itself was not fully seated in the blind hole it sits in. The rod was partially pushed in allowing clutch slippage all the time. Perhaps I need to open that hole up a tad. I need to look closer at the mechanism and see if I can see an issue. But at least the stock lever works fine for now. I'll put more miles on with the stock lever to verify nothing else is causing the problem.
PS
Yes, I DID put some grease on the little barrel the plunger sits in when I installed it originally. So that was rotating fine when I took it apart.
Any suggestions or input on this would be a great help.
Thanks
Bob
  
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Hellmutt
Needs a job
Posts: 2013
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posted August 30, 2010 11:03 AM
Could possibly have been an air bubble in the clutch line/cyl somewhere?? Dont know for sure..........Sounds like you asked the question and figured it out in the same breath man!! I can't think of any other possibilities since you've re-installed the oem lever and all is good -- interested to know what you find out since I've got a pair of ASV shorty's on my grocery list too
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British flying couch with endtables and an orange thumper
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NINJA12
Needs a job
Posts: 3310
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posted August 30, 2010 11:12 AM
Your clutch plates are worn.
The clutch level releases the clutch pressure, not apply.
You can try to bleed it but i don't expect much help.
Time for a new clutch.
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Gruntle
Parking Attendant
Posts: 28
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posted August 30, 2010 12:12 PM
I was riding with my buddies just yesterday and exactly the same thing happened to one of them on his 14. He had just installed new levers (not sure if they were ASV, just know they were not Pazzo). Engine would rev to limit regardless of gear, for no reason. He switched back to stock levers and the problem disappeared.
We concluded that the hole in the lever was not deep enough (likely just a few thou short). He's going to drill a bit at a time and test the results.
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TooHype
Expert Class
Go Hard or Go Home !!
Posts: 427
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posted August 30, 2010 06:36 PM
 Edited By: TooHype on 31 Aug 2010 03:00
Very interesting.......What is the most miles you guys have put on a stock 14 clutch pack before slipping?
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Go Hard or Go Home !!....2007 Diablo Black ZX-14, BMC Race Filter, Brock's Alien Head, Brock's Radial Mount Strap, PClll with Custom Map, Flies removed, Muzzy fan, Muzzy lowering links, Muzzy Fender Eliminator, 16/41, Speedohealer, Stretched 6", Lowered 3" IN GOD I TRUST !......If You’re a Hater….KILLYASELF !!
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gumbybob
Novice Class
Posts: 73
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posted August 31, 2010 03:52 AM
quote:
I was riding with my buddies just yesterday and exactly the same thing happened to one of them on his 14. He had just installed new levers (not sure if they were ASV, just know they were not Pazzo). Engine would rev to limit regardless of gear, for no reason. He switched back to stock levers and the problem disappeared.
We concluded that the hole in the lever was not deep enough (likely just a few thou short). He's going to drill a bit at a time and test the results.
I was thinking the same thing.
Drill the hole out just a bit deeper (and maybe a bit larger diameter) to make sure the plunger seats right at the bottom of the hole. If I DO put the ASV lever back on, I'll carry the stock lever with me just for a little insurance. I can always switch it back in 5 minutes on the side of the road.
(Man....I HOPE it's not the clutch plates that's bad)
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Hellmutt
Needs a job
Posts: 2013
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posted August 31, 2010 07:42 AM
Seems like the concensus is the clutches cylinder pin bottoms out in the levers' seat..........if that is truly the case - it's bullshit ASV's getting $250/pr. for these levers
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British flying couch with endtables and an orange thumper
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SLVR_BLT
Zone Head
Chicken Strips!
Posts: 589
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posted August 31, 2010 09:53 AM
Edited By: SLVR_BLT on 31 Aug 2010 17:57
quote:
I recently installed ASV levers (long clutch/shorty brake) and love the look & feel of them. I have maybe 300-400 miles on the bike since the change-over with no issues at all....until now. Yesterday, I went for a ride with the boys and after 50-60 miles, whenever I gave the bike some gas, the clutch slipped like crazy (say 50MPH in top gear, open her up and it would spin up to 7000-8000rpm). Felt like the back tire was slipping, but it was all clutch slip. The engagement for the clutch was feeling like it was all the way out ( I don't believe there's adjustment for that. There's only adjustment for distance from lever to bar like stock). If I pulled the lever in just a tiny amount, the clutch was disengaged. So I believe it was the lever. I put the stock lever back on and it ran just fine after for the few miles I rode after that..
SO....it seems like the rod in the clutch lever that engages the clutch in the mechanism itself was not fully seated in the blind hole it sits in. The rod was partially pushed in allowing clutch slippage all the time. Perhaps I need to open that hole up a tad. I need to look closer at the mechanism and see if I can see an issue. But at least the stock lever works fine for now. I'll put more miles on with the stock lever to verify nothing else is causing the problem.
PS
Yes, I DID put some grease on the little barrel the plunger sits in when I installed it originally. So that was rotating fine when I took it apart.
Any suggestions or input on this would be a great help.
Thanks
Bob
I had this very same problem with the same levers, you MUST use the shorter plunger pin that comes with the lever kit, you cannot use the stock ones!!! The stock ones are too long so it puts a preload on the clutch. Why it doesnt happen right away is because it gets worse when the heat starts to get hotter as the fluid expands it puts more preload on the clutch slave causing it to slip. Mine didnt slip at first but after 2 weeks and one hot day later, it was slipping like a blown clutch. I traced it back to the darn plunger king pin because the clutch lever felt funny to me after things got hot.
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2006 Kawasaki ZX14, Muzzy Full Titanium Exhaust w/ Carbon Can, PCIII, BMC Street Filter
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Hellmutt
Needs a job
Posts: 2013
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posted August 31, 2010 10:07 AM
quote:
quote:
I recently installed ASV levers (long clutch/shorty brake) and love the look & feel of them. I have maybe 300-400 miles on the bike since the change-over with no issues at all....until now. Yesterday, I went for a ride with the boys and after 50-60 miles, whenever I gave the bike some gas, the clutch slipped like crazy (say 50MPH in top gear, open her up and it would spin up to 7000-8000rpm). Felt like the back tire was slipping, but it was all clutch slip. The engagement for the clutch was feeling like it was all the way out ( I don't believe there's adjustment for that. There's only adjustment for distance from lever to bar like stock). If I pulled the lever in just a tiny amount, the clutch was disengaged. So I believe it was the lever. I put the stock lever back on and it ran just fine after for the few miles I rode after that..
SO....it seems like the rod in the clutch lever that engages the clutch in the mechanism itself was not fully seated in the blind hole it sits in. The rod was partially pushed in allowing clutch slippage all the time. Perhaps I need to open that hole up a tad. I need to look closer at the mechanism and see if I can see an issue. But at least the stock lever works fine for now. I'll put more miles on with the stock lever to verify nothing else is causing the problem.
PS
Yes, I DID put some grease on the little barrel the plunger sits in when I installed it originally. So that was rotating fine when I took it apart.
Any suggestions or input on this would be a great help.
Thanks
Bob
I had this very same problem with the same levers, you MUST use the shorter plunger pin that comes with the lever kit, you cannot use the stock ones!!! The stock ones are too long so it puts a preload on the clutch. Why it doesnt happen right away is because it gets worse when the heat starts to get hotter as the fluid expands it puts more preload on the clutch slave causing it to slip. Mine didnt slip at first but after 2 weeks and one hot day later, it was slipping like a blown clutch. I traced it back to the darn plunger king pin because the clutch lever felt funny to me after things got hot.
Do these alternative plungers come with the levers? Or is this something that needs to be ordered as well?
____________
British flying couch with endtables and an orange thumper
________________________________________________
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SLVR_BLT
Zone Head
Chicken Strips!
Posts: 589
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posted August 31, 2010 10:16 AM
quote:
quote:
quote:
I recently installed ASV levers (long clutch/shorty brake) and love the look & feel of them. I have maybe 300-400 miles on the bike since the change-over with no issues at all....until now. Yesterday, I went for a ride with the boys and after 50-60 miles, whenever I gave the bike some gas, the clutch slipped like crazy (say 50MPH in top gear, open her up and it would spin up to 7000-8000rpm). Felt like the back tire was slipping, but it was all clutch slip. The engagement for the clutch was feeling like it was all the way out ( I don't believe there's adjustment for that. There's only adjustment for distance from lever to bar like stock). If I pulled the lever in just a tiny amount, the clutch was disengaged. So I believe it was the lever. I put the stock lever back on and it ran just fine after for the few miles I rode after that..
SO....it seems like the rod in the clutch lever that engages the clutch in the mechanism itself was not fully seated in the blind hole it sits in. The rod was partially pushed in allowing clutch slippage all the time. Perhaps I need to open that hole up a tad. I need to look closer at the mechanism and see if I can see an issue. But at least the stock lever works fine for now. I'll put more miles on with the stock lever to verify nothing else is causing the problem.
PS
Yes, I DID put some grease on the little barrel the plunger sits in when I installed it originally. So that was rotating fine when I took it apart.
Any suggestions or input on this would be a great help.
Thanks
Bob
I had this very same problem with the same levers, you MUST use the shorter plunger pin that comes with the lever kit, you cannot use the stock ones!!! The stock ones are too long so it puts a preload on the clutch. Why it doesnt happen right away is because it gets worse when the heat starts to get hotter as the fluid expands it puts more preload on the clutch slave causing it to slip. Mine didnt slip at first but after 2 weeks and one hot day later, it was slipping like a blown clutch. I traced it back to the darn plunger king pin because the clutch lever felt funny to me after things got hot.
Do these alternative plungers come with the levers? Or is this something that needs to be ordered as well?
When you buy new ASV levers, it comes with 3 different plungers labeled for different bikes (probably because the same lever fits like 4-5 other bikes). The one i used was labeled Kawasaki 636, but either way it worked. You have to be careful assembling the brake side too, because it comes with 2-3 different brake switch paddles, and the ones that come on there isn't the correct one for the ZX14.
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2006 Kawasaki ZX14, Muzzy Full Titanium Exhaust w/ Carbon Can, PCIII, BMC Street Filter
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Hellmutt
Needs a job
Posts: 2013
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posted August 31, 2010 11:04 AM
Thanks for the heads up, plan on getting them later this year and the more I know beforehand, the easier they'll be to install
____________
British flying couch with endtables and an orange thumper
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gumbybob
Novice Class
Posts: 73
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posted August 31, 2010 12:30 PM
I haven't had problems with the brake side YET.
I'll keep you informed.
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SLVR_BLT
Zone Head
Chicken Strips!
Posts: 589
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posted August 31, 2010 01:10 PM
quote:
I haven't had problems with the brake side YET.
I'll keep you informed.
Granted the ones ive got were prototypes given to me by buy a former ASV employee way before they were actually released publicly so some small details were overlooked but i managed to make them work with the included parts.
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2006 Kawasaki ZX14, Muzzy Full Titanium Exhaust w/ Carbon Can, PCIII, BMC Street Filter
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