Transmission Rattle noise at start up -FIX - Kawasaki Z1000 Forum: Kawasaki Z1000 Motorcycle Forums
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post #1 of 71 Old 08-11-2013, 11:35 AM Thread Starter
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Transmission Rattle noise at start up -FIX

Some of the 3rd Gen Z1000/Ninja1000 make a rattle noise at cold start when the clutch is disengaged (lever pulled in).

I believe that the noise is caused by the clutch plates being dry and rattling against the clutch hub/basket.

Here is a video of the noise.

2011 Z1000 clutch noise - YouTube

When I removed the clutch plates from that bike the plates were very dry, normally they are coated with oil.

After the modification the owner said that the clutch was smoother and the noise is gone.

Here is the modification.

1st - Remove the clutch plates, make sure to keep them in order.

2nd - Remove the clutch hub.

3rd - you will want to use a 1/8 inch drill bit to drill holes in the clutch hub.

You have to be careful not to drill into the spring bosses and the webbing that is used to strengthen the clutch hub.

Notice that the holes go over and up and after the 4th hole you will start over at the bottom.

I had to skip 2 holes because they would have gone into the webbing.







The new holes in the clutch hub allows the oil that gets into the center of the clutch hub to get into the clutch plates better but we still need to supply some additional oil into the center of the clutch hub.

This picture is an exaggerated example of the flat that you will need to grind on the clutch release rod.



The diameter of the shaft is .417+/-

You will want to grind a .010 flat.

Now using a service manual reassemble the clutch assembly.

I use and recommend Yamalube 10w-40 conventional motor oil.

I plan to do this mod to my bike and when I do I will get some photos of the operation.

"If we have learned anything from zombies it is that once you have had human flesh you canīt be trusted to stop by the store the next time your hungry." - Repair
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post #2 of 71 Old 08-11-2013, 12:33 PM
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WOW, that video makes that clutch sound like a "Duc". Glad to know it's a simple fix. Can you reuse the clutch cover gasket?
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post #3 of 71 Old 08-11-2013, 03:00 PM Thread Starter
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WOW, that video makes that clutch sound like a "Duc". Glad to know it's a simple fix. Can you reuse the clutch cover gasket?
I wouldn't reuse the gasket.

"If we have learned anything from zombies it is that once you have had human flesh you canīt be trusted to stop by the store the next time your hungry." - Repair
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post #4 of 71 Old 08-11-2013, 06:29 PM
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Many thanks to Repair for his time and assistance with this fix on my bike! It even shifts a bit smoother too.
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post #5 of 71 Old 08-11-2013, 07:21 PM
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I wouldn't reuse the gasket.
I figured that but wanted to make sure. My last question is what the total time spent on the mod. I'm guessing a weekend project.

Jose
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post #6 of 71 Old 08-11-2013, 08:15 PM Thread Starter
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Once we figured out the fix I think that I can do mine in an hour or so but I have a full bike lift and tools at home.

"If we have learned anything from zombies it is that once you have had human flesh you canīt be trusted to stop by the store the next time your hungry." - Repair
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post #7 of 71 Old 08-11-2013, 08:17 PM Thread Starter
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Many thanks to Repair for his time and assistance with this fix on my bike! It even shifts a bit smoother too.
Glad to help and a big THANKS to you for the assistance with Kawasaki.

"If we have learned anything from zombies it is that once you have had human flesh you canīt be trusted to stop by the store the next time your hungry." - Repair
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post #8 of 71 Old 08-12-2013, 03:51 PM
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nice will this mod help with clutch wear? i mean will it make it last a little longer.
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post #9 of 71 Old 08-12-2013, 04:01 PM Thread Starter
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nice will this mod help with clutch wear? i mean will it make it last a little longer.
It should, a dry clutch plate can not keep itself cool and heat in a clutch plate means wear.

I rebuilt automatic transmissions for 20 years and they all have holes in their clutch hubs to lube the clutch plates.

"If we have learned anything from zombies it is that once you have had human flesh you canīt be trusted to stop by the store the next time your hungry." - Repair
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post #10 of 71 Old 08-12-2013, 05:52 PM
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did u come up with the fix or did Kawasaki?




03 z1000 muzzy header, & shortened muffler, pc3 usb, k & n filter, airbox top cut out, disabled secondaries, accel pump on, custom map, +4 degree ignition advancer, lightened flywheel, 15/40 gearing, speedo healer, steering damper, more mods to come....
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