Motorcycle Repair: kawasaki zx600 clutch, kawasaki zx600, kawasaki service manual

Question
I have a 93 zx600 e1 - the clutch was partially taken apart when I got it. I put it back together following the clymer manual, but the release lever won't swing to 80 or 90 degrees - more like 120. If I remove the springs and pressure plate, leaving just the push rod sitting free, swinging the release lever to 90 degrees pulls the push rod forward, out of the transmission shaft.

I didn't have to bolt the clutch hub in - that was already there, so I don't know how that's put together. It seems like the whole assembly needs to be forward just a few mm. I guess adding another clutch plate and disc wouldn't be a good idea.

Thanks
Andy
atg11@shaw.ca

Answer
Hi Andy,

We get what we pay for, so to speak. Clymer and Haynes manuals lacks clarity.

I recommend that you spend a few extra dollars and get a copy of the Kawasaki service manual.

I need to see the parts to understand what you're describing.

It's usually caused by placement of the lever upon assembly, if that's what you mean. You'll have to try and figure out how to position the lever and then install it so that it works properly when installed.

Nope, can't add more drive/driven plates.

Try visiting either "www.buykawasaki.com" or "www.bikebandit.com" to view parts microfiche. You'll have to navigate the websites to get to the menus that opens the microfiches.

Respectfully,
Mark Shively