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Clutch Adjustment - Kawasaki KZ500 Manual

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Be careful not to cut the kill switch wires
on the edge of the throttle grip housing.
2. Slide the grip back and grease the handlebar
under the grip and the cable end (Figure 16).
Reassemble the twist grip housing, fitting
the upper housing peg into the hole in the
handlebar. Check that t h e grip works
Speedometer/Tachometer Cables
Disconnect the cables at the lower end. Pull
the inner cable out, apply a light coat ofgrease
and reinstall the cables. You may have to rotate
the wheel to allow the speedometer cable to
seat. If the tachometer cable won't seat, rotate
the engine with the starter. Tighten the cable
fasteners securely.
Ignition Advance
To lubricate
t h e
mechanism, refer t o Ignition Advance in
Chapter Four.
Clutch Lever Play
The clutch cable should have about 1/8 in.
mm) play at the cable end of the lever
before the clutch starts to disengage (Figure
17). Minor adjustments can be made at the
hand lever; loosen the locknut, turn the
adjuster as required and tighten the locknut.
According to the maintenance schedule
(Table 1) and whenever t h e hand lever
adjustment range is used up, adjust the clutch
release as described here.
Clutch Release Adjustment
As the clutch cable stretches, cable play will
exceed the range of the cable adjusters. As the
clutch plates and discs inside the engine wear,
the clutch release must be adjusted even when
the cable play is within tolerance or the clutch
can drag and cause rapid wear. Adjust the
clutch as follows.
I . In front of the engine, loosen the clutch
mid-cable adjuster locknut and shorten the
adjuster all the way (Figure 18).
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