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1982 AND LATER SERVICE INFORMATION
265
CHAPTER FIVE
CLUTCH
CLUTCH RELEASE MECHANISM
(ZX550-A1 AND A2)
Clutch wear limits for the KZ550-F1 and
M1 models that differ from 1982 and earlier
models are found in Table 11.
CLUTCH RELEASE MECHANISM
(KZ550-F1 AND M I )
1. Loosen the clutch cable adjusters at the
handlebar (Figure 36) and at the engine
(Figure 37).
2. Disconnect the clutch cable at the engine.
3. Turn
the
clutch
release
lever
counterclockwise and pull it up and out of the
crankcase.
4. Examine the clutch release lever for signs
of wear and damage. Replace it if necessary.
5. Before installation, replace the O-ring on
the bottom of the clutch release lever.
6. Install the clutch release lever into the
crankcase as shown in Figure 37. Be sure a
clearance of about 1/8 in. (2-3 mm) is
maintained between the clutch release lever
and the top of the clutch cover when the lever
is turned completely clockwise.
7. Attach the clutch cable to the clutch
release lever. Adjust the clutch cable as
described in the Chapter Three section of this
supplement.
The clutch release mechanism has been
changed on the
ZX550.
To remove the unit,
disconnect the clutch cable at the engine.
Turn the release lever counterclockwise and
pull the lever out of the clutch cover. To
install, insert the release lever into the clutch
cover so that the arm is at an 80 degree angle
to the clutch cable as shown in Figure 38.
Install the clutch cable and adjust it as
described in the Chapter Three section of this
supplement. After installation, check the
clearance between the clutch release lever and
the top of the clutch cover when the lever is
turned clockwise. The clearance should be
3/32-1/8 in. (2-3 mm). If not, remove the
clutch release lever and reinstall.
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