having the same issue on 78 kz400. I think i put the ball back into my clutch but ill need to check.

It ended up that the screw at 5:13 was stripped. Fixed it with a tap and die.

Did you ever come to a resolution to this issue? I'm having the exact same problem you're describing here. Help would be appreciated!

so how did you fix it? i think i have the same problem on my bike. kz440B

I coud use some help on my 440 ltd. If you could help me, that would be great.

Number 16 the pressure plate has two holes in it that need to line up with the lines on the clutch plate holding thing

What happened to the sound?

nice bike i bought a 1983 kz440 last month i need to do the swing arm bearings etc. the clutch cable is easy to do just gotta loosen all the adjustable's til the cable gets tight and go from there if u it wont work then ur cable is stretched and u should have everything or ur gonna have problems if u havent fixed it u prob have fixed by now tho lol

I added a kick start to an 83 ltd 440. Everything worked, spun and shifted when I put the lower and upper cases together. I put the clutch back together and was puzzled about the service manual requiring a ball behind the puller. I didn't remember one or save one during disassembly. I installed it anyway thinking that it may have rolled out. It seemed like a nonsensical part but I know not to trust that instinct. Things went together okay but in hindsight the cover plate needed a "snap" to seat it. Everything is together, case cover installed. It won't shift, the primary rolls freely (neutral), and the clutch is very tight. Too tight. I suspect that the ball was never intended to be put in later models. You'll notice that the clutch actuation was changed around 1980(?) from shifter side to primary side. I'm gonna give it a whirl without the ball. It drove me crazy that I didn't have the ball from disassembly but Im beginning to think it wasn't there rather than lost. What purpose does it serve in the late model "right" side (primary) arrangement. Feel free to email me at rls43185@gmail.com. Jason.

Why cut the video?

I had the same problem had to order a new clutch cable

so....ball or no ball?

You know...yeah well you know

BTW, I'm sure the necessity will become apparent after I remove the ball. Lol.

and the the diagram 25 is the wrong part its suppose to be the part in the second diagram part number 15 thats the right one lol