New short clutch lever will not fully spring back - KawiForums - Kawasaki Motorcycle Forums
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post #1 of 4 (permalink) Old 05-19-2018, 11:19 PM Thread Starter
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Location: TN - USA
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Unhappy New short clutch lever will not fully spring back

Hello all, I just installed a new set of Ride It shorty levers on my '02 ZX6-R, they look great. Only problem is, now the clutch lever will not spring back fully, every time I shift I have to push it up a little bit so that the clutch fully disengages I have read a lot of threads similar to what is going on with my bike, no luck on this particular situation, so here I am!

If I am just cruising along at a lowish RPM and without rapid acceleration, everything is fine, if I dont finish pushing out the clutch lever manually. But, as soon as I hammer on the gas it seems the clutch engages and causes something like a false neutral. As soon as I let off the throttle, the RPMs come down and the clutch disengages once again. I also noticed that its not just the lever itself, but the piece ontop of what I assume is the crankcase? It also does not spring back all the way with the clutch lever, but returns with the lever as I push it back out..

I have tried using the adjuster wheel next attached to the lever assembly, and have went both directions with no luck, loosening it makes it much worse, which is pretty obvious I would think.. Also messed with the lever distance adjuster, have it all the way out -1 notch is where it sits right now, bringing it in further made it worse. I currently have it tensioned just about as much as it will go. ALSO, this is not play in the lever either, it just straight up doesnt spring back to where it should be... I am by no means a mechanic that is for sure, but Ive been known to pick up a tool in my day. ANY input on this would be greatly appreciated! i hope I painted a decent enough picture for you guys, I can take a video in the future if necessary! Thanks all!

AceTS - 2002 ZX6-R
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post #2 of 4 (permalink) Old 05-20-2018, 12:44 AM
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Location: SouthWest Missouri 2002 ZX-6R
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Sounds like the lever is binding on the pivot point somehow. Try loosening the mounting bolt and see if it goes away.

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post #3 of 4 (permalink) Old 06-17-2018, 11:06 PM
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Location: Jeffersonville IN
Posts: 230
couple things to check here. there should be a spring on the lever leaving your clutch case. make sure it is still there. there is a certain amount of freeplay (from the spring) that should be standardized by the manual.

if that is fine I would begin by checking the condition of your clutch cable. if the clutch cable is improperly set with these new levers you may see new problems.

finally if both of these are fine it may be the levers themselves.. I buy cheap Chinese levers of EBAY and I have to shave some of the part down because they are not "Perfect to spec" my last set I had to sand off just the slightest amount off my levers at the attachment point where they drop into the guide because they were sticking and not allowing my brakes to release.

Best of luck.

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post #4 of 4 (permalink) Old 06-11-2019, 12:26 AM
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clutch cable is out of adjustment at the case

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