You are probably off on the index of the pressure plate to the clutch basket. It's not easy to see. The plate mounts in only one of the three options..... There is a tab and slot arrangement in the lip of the basket. When it's correct the plate sits deeper on the basket. The lever will engage as you would expect automatically as you put the cover on.

 

^ First thing I'd be looking at as well.

great answers....

next up is there supposed to be 2 friction plates in that outside chanenel??? in your stack of frictions........

The last several clutches I have had to replace has only had 1 out there

...................edit.................I see on the video heading it is 05/06...... so yes, only 1 friction out in that secondary outer clutch hub chanel as I recall.... appears you have the service manual give it a look

(looking at your outer clutch basket and how all the frictions align in a single chanel sans you have two in the short slot....... most bikes only have 1 out there)

Not sure your year and been so long since I even looked at a zx6r clutch, maybe 2 belong out there, but maybe it is only 1.... ??

a couple other things..... what does the end of your shifter arm that goes through the cover look like?

slipper clutch and I assume this is new plates?--did you measure stack height?- if too tall (grossly so) you would screwed on disengagement.......... sadly I have had aftermarket kits bite me in the ass that a few customers have brought for their bikes...... so are these oem plates and at the proper stack height???

then of course there is the slipper mechanism itself, the ramps are lined up?

there simply aren't that many options of where the problem could be

 

^ First thing I'd be looking at as well.

 

I think Rivverz is onto something on those last two clutch plates. I haven't touched a 05-06 clutch in a hot minute so I'd have to see it in person and play with the orientation of the plates and all that to see what exactly is installed wrong.

 

Thanks guys I'll mess with the plates some more, I did mess with the pressure plate and got it in the right way and it still doesn't work, I'll try messing with the last friction plates, if not the shop near by is busy for about a week so I might drag it over there if I cant get it by then

 

+1 on an issue with the last 2 friction plates. There should only be one in the "short channel". You can see the wear mark from where the second one used to be but isn't now.

In other words, there should only be one friction plate offset. The rest should be in line with the deep channel.

 

First thing my eyes went to also... two plates in the position that there should only be one.

 

2005 manual states one plate

 

Nailed it KawasakiBrad AND POWERGROOVE. You def see the spots covered by the old plates where there is discoloration.

 

I know this is an old post but did you ever resolve this issue I am having the same problem ?

 

I’m having the same issue not sure if you figured it out yet

 

The physical stack up of the pressure and friction plates in the motorcycle clutch is critical to how it works. This typically includes a slightly different design for the first and last friction plate as well as the orientation of any springs in the system. The shop manual for your bike will identify all of these elements. There is additional concern with stack height. Aftermarket clutch kits do not have the same thickness as OEM for the friction plate. This may make the stack too tall or too short. The working height is extremely important.

Once that is all sorted out the last remaining part as to ensure the pressure plate which locks the stack together and allows the throughout arm to spread the plates and disengage the clutch, must be at the proper distance from the plates. That distance is controlled by the tabs and slots that mate the plate to the end of the clutch basket. My 09 has a keyed tab. Which must be placed in the correct slot on one of the ends of the basket. The pressure plate can be oriented and more than one relationship to the basket. Only one is correct.

 

What would the difference be between the friction plates I've seen the difference between the first and last steel plates but the friction plates all seem the same to me on my Barnett clutch pack for a 2013 zx-6r

 

When you look at the parts diagram the first and last friction are populated with less material. The thickness of the frictions may be thicker or thinner than OEM. You have to measure the total stack .

 

I will re measure I didn't notice a difference