Question about 1988 kawasaki ZX 400
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Posted on Jan 02, 2017
SOURCE: Grabby clutch in 1st.
I'll bet you replaced the "fiber" plates only in which case you need to either take the steel plated out and have them sand blasted, or preferably "glass beaded", you have a hot spot on one of the plates which is causing the clutch to be "grabby" also not sure if you replaced the clutch springs but if you did and they are after market they may be to high of spring pressure.
Did you install a stock clutch or a after market one? Many times the after market hi-performance clutches are made with aluminum plates and then they add the fiber and the clutch will chatter because the engine HP to to substantial for the aluminum to handle. I highly recommend using the stock Yamaha clutch plates and springs. They are of the highest quality and are the best to use.
Please let me know what type of plates you are running and I'll work from there with you. Also if you cannot get the plates blasted you can take them out and rough them up on your garage floor. Your want to use even pressure and move in a circular motion to scratch them up. Make sure you clean them afterward in mineral spirits. You can buy that at any paint store real cheap.
Posted on Dec 12, 2008
your clutch has a throw out bearing of sort i forgot what its called but its your problem your best answer is to get ahold of a group called atsg (atumotive transmission service group) they can best tell u the problem and if u want u can order a guide that shows u everything
Posted on Mar 09, 2009
SOURCE: ktm 125 sx 08 stuck in 1st gear
You have a bent shift fork and possibly something else going on. The engine will need to come out of the bike. Remove the top end, the flywheel and electrics, the clutch, the shift mechanism and kick starter and a few other parts. THEN you are ready to split the gearbox to get to the crankshaft, gears and shift forks.
You will need an impact driver, flywheel puller, case splitter, torque wrench and factory service manual, plus the normal screwdriver, pliers, etc.. Alternate to the special tools is taking it to the dealer and say "Fix it". I often tell people to take it to the shop just so they don't get into such an involved project and they now have a knowing eye and experienced hands working on the problem.
The repair cost will probably be $800 or so.
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Posted on Jun 21, 2009
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