Kawasaki Z400 - Service manual > Clutch Lever and Cable

Clutch Lever Free Play Inspection

• Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter.

Clutch Lever Free Play Adjustment

• Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter

Clutch Cable Removal

• Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter)
• Loosen the locknut [A] at the clutch lever, and screw in the adjuster [B].
• Line up the slots [C] in We clutch lever, locknut and adjuster, and then free the cable from the lever.

• Slide the dust cover [A] at the clutch cable lower end out of place.
• Remove the clutch cable lower from the clutch cover [B] loosening the locknuts [C].
• Free the clutch inner cable tip from the clutch release lever.
• Pull the clutch cable out of the frame.

Clutch Cable Installation

Run the clutch cable correctly (see Cable, Wire, and Hose Routing section  in the Appendix chapter).

Adjust the clutch cable (see Clutch Operation Inspection in the Periodic Maintenance chapter).

Install the removed parts (see appropriate chapters).

Clutch cable Installation

• Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter.

Clutch Lever Holder Installation

• Install the clutch lever holder so that the punch mark [A] to the center to the slit [B] of the clutch lever holder.
• Tighten: Torque -Clutch Lever Holder Clamp Bolt 6.8 N-m (0.69 kgf*m, 60 In-lb)

Clutch Lever Removal

Remove: Clutch Cable Upper End (see Clutch Cable Removal) Left Switch Housing (see Handlebar Removal in the Steering chapter) Starter Lockout Switch Screws [A] Starter Lockout Switch [B]

• Remove: Clutch Lever Pivot Locknut [A] Clutch Lever Pivot Bolt [B] Clutch Lever [C]

Clutch Lever Installation

WARNING

If the starter lockout switch pin has been damaged the starter lockout system will not work properly.

This allows the motorcycle b be started in gear with the clutch lever released (clutch engaged), creating sudden forward movement that can result in an accident or Injury.

Check that the starter lockout switch operates properly when Installing the clutch lever

• Replace the clutch lever pivot locknut [A] with a new one.
• Apply dime grease to the clutch lever pivot bolt [ B].
• Install the clutch lever [C] and clutch lever pivot bolt and locknut.
• Tighten: Torque -Clutch Lever Pivot Ben: 5.5 Nm (0.56 kgf*m, 49 in-lb)

• Install the starter lockout switch [A].

Take care not to damage a pin [B] when installing the starter lockout switch.

• Apply a non-permanent locking agent to the starter lockout switch screws [C].
• Tighten the starter lockout switch screws.
• Install: Left Switch Housing (see Handlebar Installation in the Steering chapter) Clutch Cable Upper End (see Clutch Cable Installation)
• Adjust the clutch cable (see Clutch Operation Inspection in the Periodic Maintenance chapter).
• Check that the pin of the starter lockout switch moves smoothly.

WARNING

Too much cable play can prevent clutch disengagement and cause an accident resulting In serious Injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch outer cable Is fully seated in Its fitting, or it could slip into place later, creating enough cable play to prevent clutch disengagement.

See also: