My beautiful Red 2014 has 19K miles on it (every one put on by me). Recently replaced hydraulic fluids - cheated on clutch by using turkey baster. Possibly unrelated, I started having a soft clutch lever ONLY on upshifts from 4th to 5th. Otherwise all normal. Replaced fluid and bled clutch to no avail, but discovered that softness existed in 5th gear, and that it was responsive to throttle input. Then, a rattle developed. I immediately went home (1/2 mile) and tore clutch down to the point of removing the basket, looking for trouble and finding none (hoping for broken anti-backlash springs). The rattle went away with no clutch parts present, and came back when re-assembled. After about eight hours trying to diagnose, I trailered to the dealer (mechanic there has very good reputation). They thought a circlip might have popped off the transmission shaft, but when they tore it down, they said the five screws securing the transmission shaft plate and shift drum plate were loose - held on by only three or so threads. As a result, lots of things clashed. They would like to replace quite a few parts. Their thought was that I tore into the bike deeper than I did, and left those screws loose. I believe perhaps threadlocker was missing on assembly, and over time, the screws backed out, and that might be responsible for the clutch softness (though why only in one gear isn't clear to me).
They want more than the bike is worth to fix it, leaving me in a quandry - the bike has lots of good miles left, and I really like it - probably the last big road bike I'll ever own. I wrote a note to Kawasaki politely asking for help with this, but since I did not buy the extended warranty, I'm not holding out hope.
Any insight or advice you guys have would be welcome. Thanks. Mac
They want more than the bike is worth to fix it, leaving me in a quandry - the bike has lots of good miles left, and I really like it - probably the last big road bike I'll ever own. I wrote a note to Kawasaki politely asking for help with this, but since I did not buy the extended warranty, I'm not holding out hope.
Any insight or advice you guys have would be welcome. Thanks. Mac