2003 Clutch sticking

Rider1352 · Mar 5, 2017

Help! I recently purchased a 2003 z1000. During the test ride noticed the clutch was a bit sticky and off. I figured it just needed a new clutch cable and it was no big deal. I replaced the cable and it's no better.

When the clutch lever is pulled in it doesn't want to return all the way back out. It usually goes mostly back out but stops and leaves about an 8th inch or so to be pushed back out manually (pic attached). At some points it will stay completely pulled in all the way to the bar (pic attached of both sides of the cable). I'm starting to think the pressure plate may be shot. The clutch does seem to work fine when the lever is pushed all the way out but I also haven't pushed the bike at all yet.

Does anyone have an idea what needs to be done? I'm afraid that after years of not ridding, my excitement to get back into the saddle may have caused me to ignore what I knew didn't feel right in the test ride. Wife's going to kill me if it's serious lol!

92K1500 · Mar 6, 2017

Is the engine full of oil?

Is the clutch action smooth or does it seem to catch and then pop out?

Disconnect the cable from the bottom and see if the clutch cable/lever moves freely. If it does, grab a piece of pipe or something that you can hook onto the release arm and rotate it to see if it moves smoothly and returns. If it doesn't, rotate the release arm about 90 degrees CCW and pull it out. Inspect the slot in the side of it for burrs or irregularity that would catch. If everything is good I would suspect clutch springs or something inside hanging.

JohnJuan · Mar 6, 2017

Mine is just adjusted so that it closes that gap in the clutch lever travel to about the thickness of a quarter. This is covered under clutch cable adjustment in your manual.

Check for your year in here for a service manual that should also cover the procedure.

http://www.z1000forum.com/forum/z1000-service-maintenance/144225-free-service-manual-hosted.html

Rider1352 · Mar 7, 2017

The oil is good and the clutch seems to work smoothly as long as I push the handle the rest of the way out. Thanks for the ideas. I won't be able to look until Wednesday but I'll definitely check for burs and whatnot.

92K1500 · Mar 7, 2017

Let us know what you find.

That03z · Sep 9, 2023

So I have a 2003 z1000 and I just replaced my clutch and the rod that goes into my case keeps skipping past the rod bearing. Anyone able to help me out or tell me why it is doing this?

2003 Clutch sticking

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