Katana clutch problem

[Smallkat]

Does the clutch push piece have its bearing and thrust washer?

I think you are going to have to check the assembly part by part against the workshop manual. The manual might give you a stack height for the clutch plates pack.

[Smallkat]

Forgot the obvious one - are all the prongs on the outer clutch basket smooth? No ridges?

[Mac13]

Hi All.
In the past, I acquired a NOS clutch cable (58200 49301). Never fitted it because I already changed the clutch cable (generic one). So this morning I decided to change the cable to the original. There are many differences the main one being the length. The NOS is much shorter.
Guess what? NO DIFFERENCE!!!! Frustrated now, so leaving the clutch strip (again) until tomorrow.
All those possible suggested I will check and I will check all that I have done. Any further suggestions would be appreciated. Oh and the feel at the clutch feels good!
Cheers Boys

[Mac13]

Hi Blix.
Decided on the second round now and not tomorrow! Will keep you informed. Failure and you may see a fire near Cullercoats, will probably be a Katana burning!
Cheers buddy.

[Mac13]

Blix,
I just had the bike in gear, running on the cnetre-stand. Bike good and warm and no difference. bike stalls when selecting gear.
Clutch stripped for the second time. This time I removed the outer clutch basket. There isnothing obvious broken/missing etc.Is it possible that the out clutch basket was not sitting right on the two location holes and the gear wheel directly behind it? Grasping at straws I think. I got no idea what to do next?

[Smallkat]

When you pull the clutch in, can you see the actuating lever moving? Is the actuating pinion shaft properly engaged with the release piece? Are you working from a manual?

[Mac13]

Hi,
Blix,
The bike does not have an electrical cut off. Put the bike on the centre-stand and can run the bike through the gears. Selecting first gear and the back wheel will spin. Try to stop the back wheel spinning using the back brake and the engine will stall. Try taking the bike running and in gear off the centre-stand and the bike will stall. The strange thing is the clutch lever feels right, even has 2mm free play.

SmallKat
When assembled can watch the clutch/lever/cable all working smoothly. Fitted the cable. Adjuster at engine first and then fine adjustment at the handlebar. As I said the clutch feels good. Smooth and no noises. Its as if just not pulling the clutch lever in far enough?
I have taken all the clutch apart and everything that should be there is. I am using for reference the parts manual off this site.
I am at a total loss of how to move forward. Any suggestions would be appreciated.
Cheers

[Mac13]

Blix
As I said any would be appreciated.
Cheers buddy

[Pedda]

Maybe you got a wrong lever assy on the handle bar giving you a shorter transmission? Just an idea.
Failing that I would have a closer look at the push rod assy. You could measure the length of the relevant parts for a refference.

[Smallkat]

Isn't it a 'pull' piece? That needs to be engaged with the pinion when you close the case? IIRC my TS has a similar system and you have to make sure it engages at the right point as you replace the cover. However, I have never had a bike the same as yours, so I could be talking out of my arse. Hopefully someone knowledgeable will come along soon!