I have installed a new clutch cable on the KZ 550 I am restoring. However, to get the clutch to begin to work, I have to adjust almost all of the play out of the cable. By this, I mean I have toput the adjusting nut in the center of the cable to almost the maximum to get the clutch to work.
Does this mean that my clutch plates are worn and need to be replaced? So far, I have removed the side plate, and cleaned and regreased the through out lever. I have not yet removed the clutch side cover. After gettting everthing together, and getting it somewhat adjusted I started working the clutch. To me, and I realise I am not used to this bike yet, the clutch seemed stiff, even with the brand new cable. After working it a few times, something seemed to slip/catch inside, so that I wasn't getting full through of the lever and it didn't feel as if the clutch was releasing.
Any suggestions?

 

make sure the cable is routed right, and you can try sum cable lube. good luck!!

 

I did the clutch cable on my KZ750, and I went through the same issues you're having. You need to set the adjusting nut on the L.H. engine cover. It is really touchy and does not take too much to be "too loose" or "too tight". Expect to mess around with it for a little while to get it just right. Then, you can adjust the cable at the handlebar lever nut. As far as the stiff cable is concerned, you should just lubricate it with some good cable lube.

I also forgot, you can take out more slack by adjusting the mid section of the cable that joins the two halves together.

Good luck.

 

It would probably help me a lot if I turned the adjustment screw on the clutch release the right way![:@]

 

lol... righty tighty, lefty loosey

 

Yeah, that could make a difference.

 

hahaha, thought that was funny. hmm, sorry.

 

Yeah,I know. I went by the Clymer book, p. 39.
#4. Loosen the locknut (Figure 21), then turn the screw out until it turns freely.
#5. Turn the screw in until it just becomes hard to turn. Then turn the screw out 1/2 turn. Hold the screw in position and tighten the locknut.

It seemed to work better when I backed the screw all the wayout, then tightened the locknut. Everything seems to work much better, smoother, and easier.