which clutch kit did u put on? my first suggestion is to double check that the return spring got put back and seated correctly. it nees to go around the boss on the case and 1 end of spring on each side of the black post that sticks out of the cases.

 

it was a conversion by tb parts which uses a modenas cover and parts.You have to remove the stock bearing and arm from the gear shift shaft and I was wondering if that had anything to do with it or would that not effect the gear change. I did not have to remove the return spring but could it have jumped off when removing the original casing

 

The parts you removed for the manual clutch have no effect on how the manual clutch works.. You should check and see if the return spring came off? Cause you must have put something together wrong take your time and check to be sure everything is put together right!!

 

http://www.tboltusa.com/store/tech.php?pid=109 here is a link showing exactly what i did, any idea where i could of gone wrong, as you can see it is pretty straight forward,in standard form does the arm and bearing you remove from the gear shaft depress the clutch plates to disengage the engine from the gearbox when changing gear, this is the only thing i can think could explain the lack of resistance from the gear lever and free play when when changing gear, thank for the feed back, i ll get to the bottom of this if it kills me

 

SORTED! a return spring off a kx85 fits like a dream and has sorted the problem out, hope this helps anyone who has the same trouble

 

Jay I'm working on the same thing... can u post a pic and where to find a kx85 spring.

 

hi, im in the uk so i got the part from over here, if you google cradley kawasaki or call them on +441384 633455 they may send you one. The part number is 92081A, its the same as the original spring but is a lot thicker, hope this helps