Clutch cable replacement

1977 kz650b I just broke my clutch cable at the lever and I have a question. Is the small plate on the transmission cover for replacing the cable?

Thanks
David

Don't think your question is complete. Are you talking about the lever on the shaft?

In my 750, the shaft in the clutch cover an the lever come out easily, but I am not supposed to do that for changing cables, and does not help one bit.

adjustments, at the lever, and cover, are supposed to be as stretched as possible, and then you have to put it in place pulling the cable, strecting, as much as you can. I can get it in eventually, but has never been easy

i think what he is asking is does he have to remove the side cover. the answer is yes you do. that little plate is for adjusting after replacing the cable. make sure its seated before you put that cover back on or youll find one tight cable

Fixer answered my question. I have never taken the side cover off nut cables are pretty straight forward. What do you mean by seated?

Thanks for your help!
David

The cable's bottom end seats into the sprocket cover (that's the name for that cover), and often becomes un-seated when removing the sprocket cover and/or replacing the cable.
Find yourself a service manual for the bike. It will give you step by step dirrections on how to change the cable.
You can download a copy of the Haynes manual here: forums.kz650.info/index.php?topic=1833.0

and a different version of manual here: forums.kz650.info/index.php?topic=2540.0

Unscrew the two fasteners holding the small cover on the sprocket cover. The adjustment screw with the slot and locknut allow for resetting a mechanism the cable goes to.

Remove the sprocket cover(and possibly the footpeg assembly) to access the clutch cable attachment place.

I believe a small cotter pin is used to prevent the end of the cable from comming out of a clevis on the mechanism.

The old cable can be removed, making note of how it's routed
and wether a spring is used for heat areas.

Start at the bottom of the cable and get it positioned so it"Seats"in the fitting and then route the cable up to the handle bars. Don't forget the small spring and cotter pin as they are important.

While the sprocket cover is off, check the clutch push rod for chain lube build up and binding.

Install the sprocket cover and bolts finger tight as you may have to access this area again.

Get the end of the cable positioned in the slot/groove in the lever and install the pivot bolt.

Now comes the fun part!! Folow your shop manual for clutch cable replacement and adjustment.

When you're happy with the clutch adjustment,tighten up the sprocket cover bolts and the footpeg assembly bolts.

First turn the cable adjusters( both) so you have maximum cable slack. Then set the adjust screw under the small cover. Loosen the lock nut and turn the screw in clockwise to lightly seated, then turn the screw out counterclockwise 1/8~1/4 turn and tighten the lock nut without the screw turning. Remove the side cover and install the new cable. Reinstall the big side cover and adjust the new cable. Use the mid-point adjuster first so you can measure about 8mm between the lever and it's stop with a slight pressure. Lock the mid-point adjuster and then take up the rest of the cable slack with the lever adjuster until you get 4mm with a slight pressure on the lever.

Oh by the way there is an exception, for after 1980 550's. GPz's for sure. On them the adjuster screw is turned out counterclockwise until seated then in clockwise 1/8~1/4 turn.

thanks for the help everyone! my cable arrives tomorrow at the kawa dealership and i should have time to replace it tomorrow.

the repair manual and the ebsco host site are amazing! it should be a no brainer.... i hope.

any other profound words of wisdom?

thanks,
david

If not already fitted, this clip is nifty to hold the cable away from the exhaust header.

Click here > Clutch Cable CLIP from Z1E

Good Luck!

Don't forget to lube the cable ends liberally! Poor maintenence there always results in premature breakage.

Don't ask how I know... :laugh:

Cheers.