HELP with clutch installation... newbie

Hey guys,

I don't know too much about motorcycles, but I do a little work here and there. My clutch cable on my 1980 KZ1000E (shaft driven) was fraying, so I bought a replacement. The first replacement snapped when testing, and now I have the second replacement on.

1) I know I need a new cotter pin before moving forward, so there's that. Will a paperclip work in the meantime?

2) How do I adjust that screw and nut properly? As you can see when I pull my clutch handle in, it isn't engaging/disengaging properly.

At a loss as to what I need to do to make this work. I just want to ride again Thanks in advance for all your help, seriously.

Do you have a manual?
Steve

The 650-B2 has a spring that's between the cable eyelet and clutch release lever, as seen in attached pic (note that this model the release lever is mounted to the backside of the engine sprocket cover whereas your's appears to mount directly to the engine). The spring compresses whence the clutch is pulled; and when released, the spring helps push the lever back to start. The cable runs through the middle of the spring.

Definitely try and get a hold of a manual for your specific model.

I have a 1000E manual and can post the clutch adjustment section later today if ya want. BTW the nut on that bolt need to be loosened and you turn the screw with a screwdriver clockwise until tight, then back off a 1/4 turn and then tighten the lock bolt. You are pulling the clutch mechanism through its actuator. Stop if you don't understand, until you have the proper procedure. R

That would be awesome, thanks for all the help everybody!

Here is the manual pages on the clutch cable adjustment.

R

You need the spring. The kotter pin is not necessary. I never put it back in and have replaced 20 cables or more over the years on KZs. The cable will always break the same way, fray at the lever. No adjustment other than cable inline adjustment should be needed if a new cable installed.

Okay guys - update #1.

I totally forgot to put the spring back on, so I did that and got a new cotter pin. Got everything hooked up and realized that the metal arm (don't know the name of it) that goes over the bolt is shaped to match up perfectly with the rod that rotates (again, don't know the name, sorry).

However, I think the guy before me might have just mashed up the nut and washer against this rod so that it turned correctly. I can't get the rod to rotate to the correct position to have the metal arm swung out far enough to the right to make it work properly. I've uploaded some pics and videos. Can you all tell me what I'm doing wrong? Or if I need to fix that/how?

Thanks so much!

another video

pics, sorry for not uploading together (exceeding size limit)

There's no lock nut on that screw. The actuator arm fitts on that cam and hangs down. Do you have a manual?
Steve

Hmm, I don't think there was a lock nut when I started, but maybe I misplaced it.
And can you be a little more specific? So is it hanging correctly in the videos?
And I thought I had a manual but I can't find it.