82 kz1000ltd clutch cable issues

Hi there, I just purchased a 82 KZ, removed the clutch cable from the lever so I could install a Vetter fairing, all went well until I tried to put the cable back on the lever. It is 2 inches too short now. I can find nothing in the Clymer manual I just purchased about cable replacement. Do I need to pull the whole cover off the left side? Is there gaskets involved? Thanks for any advice. Too broke to go to a shop. David

Hello David, welcome to KZ Land!

I would venture to guess that you may have routed the cable differently and that accounts for it now seeming to be to short. As far as removing the sprocket cover, there are no gaskets you need to worry about. There are however a few other things you will have to remove first. Peg mounting bracket, shifter lever and starter motor cover (this has a gasket but is a heavy rubber one which is re-useable) Under this cover the opposite end of the clutch cable attaches to the mechanism the actuates the clutch push rod. The cable end is held in place with a small cotter pin. If the pin is broken or missing the cable end could have slipped from the holder. This also could be the cause of the cable seeming to be to short. If you don't have a Factory Service Manual (aka the KZ Bible) check here in the archives as I believe there is one available for download. If not send me a PM with an address and I'll send you one on CD.

PS: Not a lot of guys here are fans of the Vetter fairing but I love them. Have one on my 550 and it makes riding a lot more enjoyable to me.

While the sprocket cover is off, clean and re-lube the clutch rod mechanism (where the clutch cable attaches)and clean the build up of chain lube from the push rod.

Thanks for all the help guys, i pulled the side cover, cleaned everything up and got the cable hooked up as it was before. Only now, it feels like it wants to start rolling even with the clutch in. It never did that before. I tried adjusting, that made no difference. Any suggestions?

Adjust it either on the handlebar or in the middle of the cable if you are near the end of adjustment on the handle bars. Roy

I am nowhere near the end of adjustment, thats whats troubling. Is it new clutch time? The bike only has 10k on it. Before i put the fairing on, it was fine for the short time I rode it. I just purchased this bike and dont know much about it. Thanks, David

you will need to make your adjustments at the main adjuster first not at the cable save both the adjusters on the cable for last.those are for fine adjustment only. back the cable off first before you adjust the main adjuster.