what have I got into??? Clicking noise

[Foxx4Beaver]

NEW KG Clutch Factory complete kit with fibers, plates and springs (and stickers!).

that's the title.

I've never heard of KG so I'm off to research.

I've heard of em...but I've never heard anyone say they're good or bad....hopefully they'll work in your favor.

[thunder]

got parts in but want to make sure its goes together correct.

Manual doesn't tell which way the pushrod holder and ball go in.

Can't find any video on it.  I think i figured it out from a parts diagram but now it won't turn over at all and clutch feels REALLY soft. But Its out of gas so I'll see if it fires after that.

It its missing 2 washers a something called a bearing needle too from this diagram:
http://www.kawasakipartshouse.com/oemparts/a/kaw/500b278ef8700223e4791fc4/clutch

missing parts: 92046 92200a/b and 92036.  Don't know if regular washers will work or if I need exact size.

[thunder]

Ok, got gas and the noise is exactly the same. Tried to make a video but not too good. There is a definite difference in sound and vibration with clutch not engaged.  You wouldn't want to ride it with it like this.

Now when you put it in gear the bike just dies right away.

http://youtu.be/3KRm2Hoy77c

[DoldGuy]

Thunder,

I think you have found your "Noise". Order the parts listed, Bearing / Washer / Clip & install. That will take care of your soft feeling clutch.

DoldGuy

[Goat]

Noticed there is at least 1 bolt missing in your clutch cover. Make sure all bolts are in the cases, covers and are tight. As far as the washers and bearing go. They are a certain thickness and diameter so I wouldn't try hardware store washers as it might bind up and break something. Is the bushing in the clutch basket sloppy on the shaft?

[thunder]

No bushing is tight.  Im gonna order all the parts needed today. Looks like this guy just threw it together wrong. At least I hope. Found everything except the dang washer. Kawasaki wants like $14 for that!  crazy