Clutch Cable Issue

New to the site and new to owning a KZ400. I just picked up a 1977 Kawasaki KZ400. Its in really good shape with only 4000 miles but there's an issue with the clutch cable I was hoping you guys could help me out with. I was changing out the handle bars and putting all the levers and master cylinder back on, pressed on the clutch lever and it snapped. I assumed it broke and I don't have much experience fixing that sort of thing so I took it to a guy to replace the clutch cable. He ordered a new cable and went to replace it. When he got the old one out he noticed it wasn't even broken, there just wasn't any pressure on the clutch lever when pressing on it. So he put the new one on and squeezed the lever a few times. Seemed to be working fine. Then it happened again. The cable isn't broke but it just keeps loosening for some reason. Anyone know what could cause this issue? Thanks!

Needs tp be adjusted in the sprocket cover and you need a manual.
Steve

A KZ440 Factory Shop Manual (FSM) may be downloaded for free at www.kz400.com

Go to www.kz400.com

On the left-hand side of the page, scroll down to and click on Manual


On the right-hand side, scroll down to where you see

KZ440 Workshop Manual

A workshop manual for the following 440 models can be downloaded from here or here.


Click on the 2nd "here" (the 1st "here" produces an error message).

Takes a few moments to download the FSM.

Pages 22-25 and 52-56 cover the carbs.

I believe sync detail is found at pages 22-25.

Check the index for sections regarding the clutch.

Good Fortune!

it's just from not having the adjustment screw on the sprocket cover close enough. I have had that snap happen to me while on the road a few times, very irritating. I usually just don't back it off as far from seated now to make sure that won't happen. pain in the but to fix in a parking lot :whistle:

If the adjustment at hand looks like this ---



Good Fortune!

Thank you all for the quick responses. Very much appreciated!