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Originally posted by chris mason
there looks nothing wrong there, the "stem" bit as you call it should be as you describe, it can be a real barsteward sometimes but once you've done a few you get the hang of it.

sseing as though it worked fine until you clutch cable snapped i'd be inclined to think you didn't refit the cable correct, Due to the leverage of the pedal you would have been required to take some of the slack up on the actuator.

try refitting the cable and this time put a little load on the actuator arm, not enough to pull the clutch in at all, but enough to limit the movement required for the pedal to do so. There's a dot on the clutch arm, this should line up with the other dot or arrow on the clutch case once everythings done ok.

it's a straight forward job if a little fiddly depending on the "stem"

Chris

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Originally posted by mistergrumpy
Okay. Your set up looks exactly the same as mine other than your inner basket has a ball bearing set up and mine has a needle bearing job and the springs seem to have worn into yours slightly more than mine, but not too much.
Here's where I think your problem is then:


Clutch Case Bearing

At A you can just about see the top needle bearing that the actuating arm goes through on the inside of the clutch case. At B however you can see that I knocked up an ally bush on this one as an idea. There should be another needle bearing in this hole so that the arm is supported at the top and bottom when it turns. Mine didn't have this bottom bearing and so the arm was waggling around in the hole and slipping off the other clutch arm causing the problem you showed to the actuating arm.
This bearing isn't shown on Kawasaki's diagrams when I've looked its only when someone offered to sell me a replacement that it finally clicked.
Hope that makes sense. Let me know if it doesn't.

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