ZZR600 woes - clutch release rod keeps dropping out

As per subject...

Saturday before last, the clutch release rod on my bike dropped by a
centimeter or so.

Got it fixed with a new rod fitted as the old one was worn.

Used it for a couple of short trips, and then it did it again.

This time we just sort of clicked it back into place without taking the
clutch cover off.

Bike works fine for the rest of the week, then does it again this evening.

Mechanic baffled. Kawasaki unhelpful. Haynes manual barely mentions
the part.

Anyone seen this before and have any suggestions for how to stop it
doing it again?

I've asked about using a smaller oil seal and mechanic is suggesting
finding a way to add a circlip onto it.

 

http://www.piaggiospares.co.uk/spares/epc2.asp?ModelID=7385&pageID=2250
I take it 13102 fits onto 46102 to push it in when the clutch lever is
pulled?
In which case 46102 must also be fucked.

Steve

 

I will ask in the morning - thanks for the suggestion.

 

That's more or less what I was going to suggest. Either 13102 is rotating
too far back when the clutch is released and disengaging from 46102 or 46102
is damaged in some way so that 13102 is disengaging and dropping out. When I
was trying to solve the sticky gearchange on mine I was surprised that there
was no positive retention of the clutch release lever.

--
Malc

Rusted and ropy.
Dog-eared old copy.
Vintage and classic,
or just plain Jurassic:
all words to describe me.