I have been working on the bike and can't seem to find a way to adjust the clutch lever to not be so heavy. By heavy I mean like REALLY heavy. I know some of the older kz's had adjustment screws, but I cant seem to find that on this bike, nor can I find instructions for adjustment in the shop manual I have (except for cable adjustment). If anyone has experienced this problem, or has any suggestions it would be much appreciated.
There should be a clutch lever thumb screw adjuster. The 550 manual is kind of ambiguous as to how to do the clutch adjustment.
After turning in the cable adjusters to get some slack in the cable (thumb adjuster & mid-cable barrel adjuster),
turn the clutch release adj screw counter-clockwise first until hard to turn, then clockwise 1/4 or 1/2 turn. It's 1/4 turn on my 81 650.
then tighten the locknut without turning the adjusting screw.
Adjust the cable adjusters so that there's about 2-3 mm of free play in the clutch lever.
Be sure to lubricate the cable, especially the clutch lever end. I use brake caliper grease on the clutch lever end.
Most likely the cable needs careful lubrication. It may also be that the release mechanism under the side cover needs to be cleaned and properly lubricated.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
