ZXR400 Clutch not disengaging

[everyreasonto]

My zxr400 has been having problems with the clutch not disengaging properly. I though this may have been due to clutch cable stretch but I changed this and I'm having the same issues.

I dismantled the clutch (Which had no gasket!) and *think* I may have isolated the problem. At the top of 5-6 in the manual - https://www.zxrworld.co.uk/Manuals/H%20Model/ZXR400%20H%20Chapter%205.pdf it says that there should be a 90 degree angle between the clutch release rod and the cable but mine isn't, it's more like 135 degrees (as in, the holder isn't pointing towards the bike but is further forward).

I removed the clutch release rod/lever and it seems to be worn at the point where the clutch release lever meets the pusher:

https://i.imgur.com/6INzK.jpg

But i'm not sure if this is normal or not because there isn't anything in the manual about it.

Could anyone confirm that replacing this part will fix the clutch because it is a fair expensive part and I'm skint!!

Ta

[thomp1983]

zxr world would be the best place to ask, you didn't remove the bracket that supports the cable adjuster did you?

chris

[CaNsA]

Cargo on ZXRworld has this to say about it.

[thomp1983]

it's not a massive issue if the op has, it's just that the tensioner will need resetting before putting the bolt in, if you don't your likely to crack either the tensioner or casting. if you have removed it id also be checking the engine timing before putting it back in

chris

[CaNsA]

So what you are saying is....

Reset the tensioner before putting the bolt back in or you will fuck the casing.

Sounds like a massive issue to me... And Cargo..... It's not like he has been building and racing the things for the past decade

[everyreasonto]

Nope

Cam chain + tensioner is something I have done on a ZXR before so I knew to stay well clear

[CaNsA]

[everyreasonto]

??? Like I say, I haven't removed the bracket, I've removed the clutch release lever

[thomp1983]