2010 ZX6R - 18K miles, mechanic-owned from new(me), lots of commuting in hilly areas in traffic, plenty of track days, no major problems until now.
If this was a car, I'd pull and machine the flywheel. But it's not, so before I go nuclear and replace the clutch basket I thought I'd ask for your help.
When you pull in the clutch, put it into first and go, engagement is not smooth, it's wobbly like a warped brake rotor is wobbly. Not bad, most noticeable on hills with cars creeping up to a light in front of you. You can find even find a point (85% lever release or so) where it grabs then releases, engages and disengages, again just like a warped brake rotor when you're feathering the lever.
Below 8 mph, when you're coasting with clutch in, waiting for the cager in front of you to get a move on, it'll intermittently clunk (sometimes several times) when you engage it, doesn't matter how much throttle you give it. Car analogy: Badly warped flywheel/clutch plate engages suddenly and chirps tires on engagement. What i think it's doing: clutch suddenly grabbing the output shaft and front sprocket slapping forward into the chain. That's what it sounds like.
What I did:
Figured I had some warped steels, was getting close to end of adjustment so I replaced clutch fibers, springs (both clutch and torque-limiting) and steels with kawasaki OEM. Noted strange wear on release lever (pic below) and replaced that as well. Snap-on torque wrench used for all fasteners, 87 in/lbs on spring bolts.
Still have same problem. Feels exactly like warped flywheel on a manual trans car.
The strange wear on the release lever seems to confirm that something is wobbling, as it wore a significant chunk of metal from the release lever. Peeking through oil fill hole while engine is running isn't definitive, but looks like it's wobbling a little when clutch is pulled.
Any suggestions would be appreciated before i pull it apart again. I suspect the clutch basket or one o the components the springs bolt to/pull on (clutch hub, clutch operating plate)
If your suggestion saves me the $350 on a clutch basket will receive eternal thanks and beer+bourbon money via paypal or vendor of your choice. Suggestions that confirm I need a new clutch basket will receive thanks and no beer or bourbon for anyone because I'll be broke.