Clutch Cable popped at hex-head adjuster

  • jaguar_shark
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Clutch Cable popped at hex-head adjuster

26 Mar 2025 13:19
#910570
Hi there, the clutch cable on my '82 KZ440 ltd popped today. I was adjusting the cable tension and must have tightened too much- when I pulled in the lever at one point the hex head adjuster popped free from the cable and now everything is completely slack.

Do I need a new cable or should I re-adjust the cable?

Thanks in advance

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  • urankjj
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Re: Clutch Cable popped at hex-head adjuster

26 Mar 2025 14:57
#910579
You might have a look at where the clutch cable connects to the engine, there could be an issue there resulting in the slack. Good luck.

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  • Scirocco
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Re: Clutch Cable popped at hex-head adjuster

26 Mar 2025 15:18
#910583
Mostly commen issue is the rusted and rotten cable inside the sheath, so to say it´s snapped inside due to the lack of maintance of some drops of lube.
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  • Michi
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Re: Clutch Cable popped at hex-head adjuster

30 Mar 2025 04:57
#910723
You'll need to replace the clutch cable. When putting the new one in, follow the procedure stipulated in the manual. The adjustment is done in 3 stages, and has to be done in the right order or it won't work. While your sprocket cover is off, clean out and grease the mechanism - this will help to give that sensitivity you need when setting the preload on the clutch pushrod side. 
KZ440A LTD (1980)

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  • H1Vindicator
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Re: Clutch Cable popped at hex-head adjuster

30 Mar 2025 06:34
#910727
brake caliper grease is good for the cable ends. it stays put and doesn't attract dirt and grit. use sparingly. lube the cable first and let any excess drip away if necessary. wipe off the ends. then apply the brake grease. 
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