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Discussion Starter #1
Okay so quick backstory. I did the engine tilt on my bike to replace a stator & rotor and I am currently slapping everything back together.

I have read through all the posts about people having problems installing the bevel gear and then having no tension on their clutch release lever. Well I have uninstalled and reinstalled this thing about two and a half dadgum times now and can’t seem to get this thing right.

The first time I installed it I definitely heard a loud “pop” when I was tightening down the bevel gear bolts. I prayed it was nothing big and kept installing it. After I had gotten all the bolts tightened back down the clutch release lever would not budge at all. I figured whatever the clutch push rod sits against in the bevel gear housing was stuck too far out So I took it off again and moved the lever till the “thing the clutch rod sits against” was in it’s lowest position.

Then I reinstalled the bevel gear and now the clutch release lever spins with NO tension in either direction for a lot of degrees and then there will be smidge of resistance (like the shaft finally hits something) and then it slips past it and spins with no tension again in either direction. It just “doesn’t feel right”.

This is how I think it works: When you pull the clutch lever at the handle it pulls the clutch release lever which turns the release shaft and the little splines at the top of the shaft push against the clutch push rod, and then what happens??? Is it possible I messed something up on the other end of the clutch rod, and that is why I am getting no resistance??

The Kawasaki manual made it seem like all of this should have been so easy….but I feel like I am missing the secret sauce of how this works, and am now worried I broke something.
 

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Discussion Starter #2
I don’t know if this is relevant to my current situation or not, but I also do not believe I disconnected the clutch cable from the release lever the way I am seeing it tells me to in the Kawasaki manual.

I knew I was going to be taking the generator side cover off anyway so I just removed the little clutch cable mounting bracket on the lower right side of the generator cover and once that came off I was able to slip the cable out of the clutch release lever.

(I may also remember hearing a loud “pop” sound when I was taking off that little mounting bracket for the clutch cable, but it was more than a week ago so the details are getting foggy on me)
 

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Discussion Starter #3
I went ahead and removed my clutch release shaft just to take a look and see if I could understand this beast a little better and it looks like on of the teeth may be tiny bit bent. Is this going to be a big problem?

I attached a picture of the clutch release shaft as reference.
 

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Hey I was curious what u did to fix this issue have the same thing happening now
Describe what's going on, because it sounds like OP had broken the "rack" ,(as in rack and pinion) that the shaft in the picture acts upon.

Does your release shaft spin freely?

If not, it could be the shaft was not set properly on installation. Has yours been taken apart?

Need more info.

Do you have the repair manual? Free download.
 

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I’m replacing the entire clutch assembly...
Was curious on how to install and adjust the push rod to get the most clutch plate extension.... any videos and tips?
 

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Check the manual, the shaft needs to be turned all the way to a certain direction before installing the lever. Forget which way, there's also a recent post about installing the lever. MTB posted which way to set it.
 
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