[BobN54]

Thanks for that Bob. I have been doing that for a while now and yes it does work but am sick of not being able to just start, warm up and ride my brand new Z1000 with out doing some Kawasaki Voodoo dance to get the bl#*dy clutch to do what it is supposed to do. This issue has been around for sometime and am surprised that Kawasaki decided the Gen 4 should have this issue also.

I concur, and understand your frustration. It's seems very strange that the problem is still around three years after it became known.

 

[nate1235]

Alright, finally got some free time today and decided to get this project done. I was replacing the old clutch basket that I accidentally broke on the previous attempt at this mod with a new, modded basket. Got everything put back together, and I noticed that my clutch cable adjustment nuts were in a totally different location than before I popped in the new clutch basket. The clutch worked, but it didn't feel right, so I drained the oil and took everything apart again to see where i messed up. As I was taking it apart, everything seemed normal, so I thought maybe I had the wrong clutch basket and this new one was a slightly different size. I started measuring the old and new basket and was comparing them when I noticed a washer/spacer that was stuck on the back of old basket! The residual oil makes it stick on there really good. If you guys decide to do this mod,

make sure you don't miss this washer!

Put everything back together with the missing part, and it was completely normal again.

That said, I'm loving the feel of this mod. There is no noise difference between clutch engaged/disengaged, and the shifts are buttery, silky smooth. It's a very noticeable difference vs stock, and I'm sure it's not placebo effect. I highly recommend anyone to do this mod.

 

[Pats bikes]

Kawasaki 305 belt 1985 clutch rattle. Due to basket cushion inserts being worn and the insert material rubber? hardening. I have taken my clutch apart and found out. I have tried to replace the inserts but cannot find a supplier.

PS. Not an easy job to to take apart.