What Would Cause A "Click" or "Knock" In The Clutch Lever? - KawiForums - Kawasaki Motorcycle Forums
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post #1 of 11 (permalink) Old 12-27-2016, 08:47 PM Thread Starter
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What Would Cause A "Click" or "Knock" In The Clutch Lever?

Hey Folks,


First and foremost, it feels great to be back in the saddle of a Kawi! Had a 2012 ZX6R, loved it to death, but wanted a bigger bike. Traded it in for an '07 Busa...plenty of power, and that was about it. The Busa got old and boring really quick (which I genuinely did not expect to happen). Anyways, just traded that in for an '07 ZX10R and I gotta say, this is the bike I've been dreaming of! (I don't care what the reviews say about the 06-07..this thing is the tits :-)

So as the title suggests, the bike is developing this issue more and more frequently, to now it happens pretty much every time I pull in the clutch. I don't know how to describe it, but under decent load, in any gear, pulling in the clutch to shift I feel a 'click' or 'knock' or 'pop' in the lever, then I click into gear with the left foot, let the clutch out, and it does it again on the way out. If I don't accelerate TOO quick, or put the engine under too much load, I won't get that clicking in the lever. Downshifting does it as well, almost every time in any gear.

If I'm in neutral, or the bike is off, I can pull the lever all day and it is perfect, so I don't think it's the lever itself.

The bike runs perfect, the actual clicking into gears up and down with the left foot is good, just the lever has that click. Possibly related, is the clutch lever requires a abnormally large amount of grip strength to pull. I checked the cable routing, it's good. No kinks or anything. I know "lube the cable!" is a common response, but I've 'been there, done that' and know lubing the cable doesn't make that much of a difference. I also opened up the cable housing, and the cable 'end' part that lodges/wedges/whatever into the housing itself is cracked, so I may just replace the cable. Just curious if this would cause my issue or if could be something else? Failing clutch, chain tension issue, etc. Any input is greatly appreciated!

Damn, it really is great to be back here! Love me some Kawis!


Shaun
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post #2 of 11 (permalink) Old 12-28-2016, 12:54 AM Thread Starter
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Took the lever assy apart. Pulled the cable out, connected the little motion pro cable luber to it, squirted cable lube into it until it started dripping out the other end by the clutch cover. Yanked off the ripped plastic piece that covers the end of the cable in the housing, and put some anti-seize grease on the pivot bolt. Still clicking/popping when pulled and released under load, and still hard as hell to pull.

Interesting - With the cable out of the lever housing, I can pull the cable with my thumb and pinky finger and disengage the clutch. It's like a feather. But as soon as it is put back in the housing, it's hard as fuck to pull. Is there something wrong with my lever?
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post #3 of 11 (permalink) Old 12-29-2016, 08:20 PM
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Try a new clutch cable first.
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post #4 of 11 (permalink) Old 01-01-2017, 05:19 PM Thread Starter
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Quote:
Originally Posted by ZZR600-2008 View Post
Try a new clutch cable first.
That's what I figured. I just put in a new cable, click *appears* to be gone, will take her for a ride a little later.

Also dealing with a fairly heavy clutch lever. I thought maybe it was the after-market shorty levers the previous owner put on, so I also put a factory clutch lever on, and the strength it requires to pull the clutch lever is the same, really tough. This is with a new cable.
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post #5 of 11 (permalink) Old 01-02-2017, 11:32 AM
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If the previous owner had a slipping clutch, they might have added washers to the clutch springs or new stronger clutch springs to stop the extra slipping, instead of adding new clutch plates.

Your best bet is adding new clutch plates and new clutch springs, while checking the clutch basket for damage.

Another option is riding it as is and getting used to the extra hand exercise. 20w-50 regular motorcycle oil helps an old clutch last longer, and most owners manuals say this weight oil is good down to 32 degrees F outside.
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post #6 of 11 (permalink) Old 01-02-2017, 12:00 PM
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Quote:
Originally Posted by sketterman View Post
That's what I figured. I just put in a new cable, click *appears* to be gone, will take her for a ride a little later.

Also dealing with a fairly heavy clutch lever. I thought maybe it was the after-market shorty levers the previous owner put on, so I also put a factory clutch lever on, and the strength it requires to pull the clutch lever is the same, really tough. This is with a new cable.
Tell me you lubed the new cable.

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a beer-drinking, pot smoking, naked bike trashing hillbilly like you has an iPOD Touch ??--cobra
Quote:
Originally Posted by Barry Soetoro View Post
"Blah blah my bike is faster than yours around a technical track". Yawn. Well I on my feet can beat your small bike in a race of 100 laps around my couch
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post #7 of 11 (permalink) Old 01-02-2017, 03:37 PM Thread Starter
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Quote:
Originally Posted by ZZR600-2008 View Post
If the previous owner had a slipping clutch, they might have added washers to the clutch springs or new stronger clutch springs to stop the extra slipping, instead of adding new clutch plates.

Your best bet is adding new clutch plates and new clutch springs, while checking the clutch basket for damage.

Another option is riding it as is and getting used to the extra hand exercise. 20w-50 regular motorcycle oil helps an old clutch last longer, and most owners manuals say this weight oil is good down to 32 degrees F outside.

Good information, thanks. I'll probably just ride it out for a while, and if it gets to the point where I can't stand it anymore, I'll take the clutch apart and have a look. I guess extra grip strength isn't a bad thing.
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post #8 of 11 (permalink) Old 01-02-2017, 03:37 PM Thread Starter
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Originally Posted by locknload View Post
Tell me you lubed the new cable.
yessir!
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post #9 of 11 (permalink) Old 01-02-2017, 06:31 PM Thread Starter
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Quote:
Originally Posted by ZZR600-2008 View Post
If the previous owner had a slipping clutch, they might have added washers to the clutch springs or new stronger clutch springs to stop the extra slipping, instead of adding new clutch plates...
Quote:
Originally Posted by locknload View Post
Tell me...

Quoting you guys just to get your attention for a sec :-) I made up a quick video on this clutch lever/cable, would be great if you gave it a watch and let me know your thoughts?

https://youtu.be/p1OJplXG4tQ
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post #10 of 11 (permalink) Old 01-03-2017, 08:04 AM
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I wonder if someone installed heavier clutch springs or possibly the clutch release bearing is starting to fail.

Quote:
Originally Posted by dwillits View Post
a beer-drinking, pot smoking, naked bike trashing hillbilly like you has an iPOD Touch ??--cobra
Quote:
Originally Posted by Barry Soetoro View Post
"Blah blah my bike is faster than yours around a technical track". Yawn. Well I on my feet can beat your small bike in a race of 100 laps around my couch
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