KZ900 clutch cable replacement

HI,

I am not a tech but do have an understanding how things work and do simple service to my bike. Could some body help in in getting information on replacing my clutch cable to my 1977 KZ900? I do not want to get into a something over my head so I am asking those who know.

Thanks,

Gary

There should be a downloadable manual for your bike on this site. Make sure you lube the new cable first, sometimes they don't come lubed.

It's not that hard. Take off the footpeg and shifter, take off the cover and you will see how it hooks up. Just getting it adjusted when you get it back together is the trick but even that is easy.

Do what Don said. It takes 30 minutes to change the cable. Then there's the much debated adjustment question. All I can say in 300,000 miles on KZs, I adjust the cable adjusters and have never once found it necessary to mess with the adjustment on the engine. Other guys here turn the bolt in till it seats, back out 1/2 turn then loosen it 1/4turn more, then adjust for 35 degree angle of the arm. Just kidding, but try putting the cable on, turn the adjusters on the new cable to get the correct play at the lever and you are all done. If the old cable worked before, the new cable will work exactly the same as the cable replacement does not make the adjustment on the engine assuming it worked before change in any way.

Hi,
Thank you all for your knowledge and advice.......I just ordered the cable and will post my outcome during or when completed. I hope the success is not determained by how many times I drop the F-Bomb.

Thanks again.

Gary

Clutch Cable Replacement On some Kawasaki Motorcycles

1.About mid way down the clutch cable is an adjuster; shorten the cable as much as possible.

2.Remove the small cover on the left side of the sprocket cover and loosen up the lock nut on the clutch throw out mechanism.

3.Remove the shifter lever; the sprocket cover, and lay the cover on some rags or news papers.

4.Have on hand a small cotter pin that will be needed to prevent the new clutch cable from coming out of the throw out mechanism.

5.At the left handlebar turn in the slack adjusters for the clutch cable and then take out the pivot bolt.

6.New clutch cables may or may not have lubrication; now's the time to either hang the new cable up overnight so heavy oil can flow through it or buy a cable luber kit with the special clamp and can of spray lube.

7.Attach the cable to the cover's throw out mechanism and secure it with a new cotter pin.

8. While you're in there, check the wiring from the alternator(YELLOW WIRES, or any wires from the alternator), remove the excess chain lube from the clutch push rod and check the wire routing that goes above the engine sprocket.

9. Check the lock washer for cracks on the engine sprocket and any "Hooking" of the sprocket teeth.

10 Route the clutch cable the same way the old one was and connect the cable to the clutch lever; and the pivot bolt gets re-installed.

11.Carefully install the sprocket cover, making sure the push rod is engaged and then tighten up the cover.

12.Adjusting the clutch play and cable tension is real easy; using a flat bladed screwdriver, turn the slotted screw clockwise(to the right) until it becomes hard to turn; then turn it counterclockwise(to the left) 1/4 turn and tighten the lock nut. If in doubt, consult your shop manual for throw out adjustment.

13.The mid way cable adjuster and lever slack adjuster may need to be adjusted for correct cable slack.

14.My factory shop manual lists 2-3mm as the correct play in the lever after the cable has been properly tensioned.

15.Re-install the covers, and shifter lever, start the engine to check the shifting action.

16.These engines have a shifting lock out to prevent moving in any gear higher than second unless the engine is running and proper shifting is done.

HI,

I would like to thank all the people that responded to my need of help in replacing my clutch cable on my KZ900. I followed directions as you all had given and it went without a glitch, something uncommon for me. There is a special connection and gratification when you can work and fix your own ride, anyway it was for me.

Thanks again,

Gary:

P.S. Not one F-bomb!

Don't ya love it when a plan comes together! :woohoo: