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Table of Contents
CLUTCH
125
SPIRAL GEAR CLUTCH RELEASE
10
1. Locknut
6. Outer gear
2. Adjuster screw
7. Bolt (2)
3. Circlip
8,
Inner gear
4.
Ball retainer
9. Cotter pin
5. Balls
(1 1), 118
in.
10. Cable spring
rotates the arm which moves toward the
clutch. The adjusting screw in the arm then
pushes against the clutch pushrod, which
extends through the hollow transmission input
shaft and releases the clutch pressure plate
from the pack of frictim and steel plates.
Early models use a clutch release with 2
spiral gears riding on 11 ball bearings (Figure
1).
Late models use a clutch release with 3 ball
bearings riding up ramps in the release arm.
1. Place the bike on its centerstand.
2. Remove the left footpeg bolt, lockwasher
and the footpeg (A, Figure 2).
3.
Remove the shift pedal (B. Figure 2);
remove the bolt. and spread the slot open with
a screwdriver if necessary. If your bike has
linkage between the shift pedal and shift shaft.
remove the circlip at the pedal and remove all
the linkage (Figure 3).
4. Remove the 2 bolts securing the starter
motor cover. and remove the cover and gasket
(Figure 4).
5. Remove the 4 bolts securing the engine
sprocket cover and remove the cover (Figure
5). Be careful not to damage the shift shaft oil
seal.
6. If you want to detach the clutch cable,
remove the clutch release lever cotter pin
(Figure 6). Remove the cable tip from the lever.
7A. On late models:
a. Pull the release arm out of the release
housing.
b. Remove the 3 ball bearings and their cage
(Figure 7).
7B. On early models (see Figure 1):
a. Remove the 2 screws that mount the
release housing to the sprocket cover.
b. Remove the circlip and separate the outer
and inner spiral release gears. Be careful
not to lose the 1 1 release balls; in case you
do, they are 1/8 in. diameter.
8. To assemble, reverse the disassembly steps.
Note the following:
a. Apply grease to all clutch release parts
before assembly.
b. On early models, the inner spiral gear
must be installed so that when the 2 gears
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   Also See for Kawasaki KZ500

This manual is also suitable for:

Zx550Kz550Kzx550

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