Motorcycle Repair: clutch not disengaging, kawasaki ninja zx7r, clutch lever

Question
Wayne,
i have a 1992 kawasaki ninja zx7r and i am experiencing trouble with my clutch. At first i thought it may have been the master cylinder but then i primed the system and it held pressure. then when i thought it was fixed i tried to put it in gear and it almost sounded like it was grinding the gears. it would kinda down shift from neutral to first but would immediately jump right back to neutral. any pointers?
thank you,
Eric

Answer
Hi Eric,

Always check the linkage and shift lever
for obstructions first. It sounds like
the clutch is not releasing for some reason.

It might be the clutch plates (discs) are warped or
stuck together. It could be wear on the clutch
hub and basket fingers which cause the plates to hang up.
http://webservices.motorsportdealers.com/parts/partImages/KUS/2/C14/C1471/E1350....
A weak or broken clutch spring could affect things too.

If your shifter and clutch lever feel okay
then the problem is likely in the clutch itself.
You could check the shifting mechanism or the
push rod under the slave cylinder for problems.

If you pull the clutch cover off you may
be able to see if the plates separate slightly
when you apply the clutch lever.

They have to separate slightly to allow
the plates to slip. If the clutch basket
or hub has wear grooves the plates may
hang up on those.
They can be filed down if minor wear is present.

If the plates do not separate slightly
then the slave push rod may be bent.
This runs from the slave cylinder through
the clutch center where it pushes the outer
clutch plate cover to release the clutch.

If you put the bike on a stand and raise the rear
wheel you should be able to put the bike in a higher gear
and turn the rear wheel by hand. Pull in the clutch
and watch if the inner part of the clutch
slips around inside the outer. If it does
then the clutch is working. The inner and outer
clutch plates have to disengage and slip for the clutch to release.

If you suspect a shifting problem then check the
shifter linkage, shift assy detent and springs
and shift drum end:
http://webservices.motorsportdealers.com/parts/partImages/KUS/2/C14/C1471/E1370....


Luck!
Wayne S.
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