Chain cover trouble

I got a new chain cover and I cannot get the clutch right. The spring for the clutch cable at the bottom is giving me grief. I can get the cover on, but the clutch lever won't disengage the clutch because it won't stay in its little inset.

Any tips or tricks for solving this would be much appreciated!

I don't know if it the same on your Gpz but on my KZ 1000 the clutch rod actuator is like a huge threaded piece that can be removed, rotated and set back in to where it looks right but......if you don't get it right it won't push the clutch release rod at the right time. Like I said it might be the same as on your bike (my shot in the dark), worth a check.

I really just cant get the end of the cable (round piece with three round slots) to seat in the chain cover.

Bluezbike, do you mean the the metal rod that runs through the whole case?

You can't get it to seat or it won't stay seated?

Did you install a cotter pin at the clutch release to help keep the cable end in place?

Is the clutch lever end of the cable hanging loose? I think it helps to maintain some tension on the inner cable to keep the clutch release end of the cable in place.

It won't stay seated. The cotter pin is in place. The clutch lever is not dangling, but it is quite loose (the lever has a full range of motion without tension). I'll try with it tighter and see what happens.

Yes I did mean the rod that goes through the input shaft....again I really don't know if it's the same on both our bikes (hope so). Also does your clutch cable have a barrel adjuster in the middle somewhere as well as the adjuster at the clutch lever?. My son's KZ 650 had to have that almost fully extended before his new clutch cable seated/operated properly

I figured out that I had a spring in the wrong place on the clutch cable, so now there's enough slack to allow it to seat, and tight enough to keep it in place. But now I have a different problem.

My clutch cable is way too loose. I have the barrel adjuster fully extended as well as the clutch lever adjuster, and there is still too much play. Not only that, but when I squeeze the lever and encounter a little resistance, the clutch cable end pops out of its inset.

I've adjusted the cable as per the manual, but it doesn't really matter since it keeps popping out of the chain cover

Did you loosen the jam nut and screw the bolt in that seats against the clutch rod? This is built in the cover.

Any luck ?

I did. No luck. Still stiff and no disengaging fully. I'm going to take it all apart and put it back together according the parts diagram. Maybe I'm missing something.

In the attached image is a part I am missing. It doesn't have a part number, so I'm assuming it's just a simple spacer.

Here's what I've deduced, correct me where I am wrong. The clutch rod hits the spacer against the clutch release. Without the spacer, the clutch rod goes all the way into the clutch release, and there's not enough pressure to fully release the clutch.

If this is it, where can I get that spacer? Could I get one from Home Depot? Is there a specific thickness?

I'm having the same trouble on my 440. cleaned up the release lever and checked the cable, reinstalled. Tried to set the cable but have to extend out a lot to get tension and when I do its hard right away. There's no area of increasing tension and there's no spring back either.

Does anyone know if you should be able to push the pushrod yourself with a tool or something and get movement? I can slide it back and forth just fine but when I tried to duplicate the action of the release lever it wouldn't budge. Makes me worry that the clutch is seized.