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Hi John, the correct clutch adjustment procedure is as follows: Loosen the jam nut on the clutch cable adjuster and screw the adjuster in about 1/2 " this should give you tons of free play at the clutch lever. Remove the the left footrest, the clutch inspection cover and slide the spring and lockplate off of the adjusting screw. Turn adjusting screw counterclockwise untill resistance is felt then clockwise 1/4 turn replace lockplate and spring, check for proper fluid level in primary and button back up. Back out the clutch cable adjuster untill you get 1/16" to 1/8" freeplay while pulling the clutch lever with your left hand and the clutch cable in the oppisite driction with your right hand. Tighten jam nut and your good to go. Good luck
On the back of the lever there is a screw and a round bolt. Unscrew that bolt until the right amount of play is in the lever you are problably going to want about 5-10mm of play in your lever. If it is to tight with no play it will start to engage your clutch ealry and possibly damage something. If you can put that screw the whole way out and you still have to much play you are going to want to replace the cable all together because it has streched and could possibly snap when riding. Good luck I hope i have answered you question A.J. Weaver
I looked up your bike and i belive that your bike has a cable clutch on it and not a hydrolic. So on your clutch lever there will be a bolt that goes into the the lever and a securing nut where the cable goes into the lever. If you unscrew your bolt the clutch get tighter and if you scew the bolt in the clutch gets looser. You should try to lubricate the cable and clutch. If it has been sitting for to long it may just be getting stuck. make sure that your clutch lever snaps back into possition. Your clutch lever has to have some play in it because if it is set really tight you will start to engage the clutch. If it is to loose then you wont be able to engage the clutch. You want about 6-10mm of play from the end of the handle bars to end of lever. So it will move that far before it will engage at all. This is a factory setting you may tighten or loosen depending on your riding style but remember the consiquences of what you are doing. if this is how your bike is set up then it is probalby your clutch plates. I hope this has helped you if you have any questions about any step just shoot me an email anytime. Good luck A.J. Weaver
Does it lurch forward a little? If so, First thing to check is the cable adjustment. As you pull on the clutch lever, you should be able to feel a little free play before the lever actually starts pulling the cable. You should have approximatley an 1/8 inch gap between the lever and the perch when lever engages the clutch.
If it's not the clutch dragging, check for a faulty kickstand switch.
Two stroke motors with wet clutches are notorious for sticking when left for a period. Older oiler will leave a slight residue on ends of friction plates. If it is a regular thing after every stop, you will need to rinse clutch with a solvent. You don't need to dismantle if you are patient and carefull when applying solvent as it may discolour alloy cases and paintwork. Use a premium grade MOTORCYCLE GEAR OIL only and your problem will be solved if your clutch is A1 mechanically.
undow the clutch lever screw the adjuster so that the cable will come out then follow the cable down to the engine undow thw nuts holding the cable remove the cable and refit the new onw in the same routing as the old one set the adjustment so there is about 1cm play at the lever
ok, three different possibilities here. first, you replaced your broken lever with a lever that has the hole for the cable end a little closer to the perch, and you dont have enough range of adjustment to tighten up the cable. this is probably the least likely scenario, since you need a very signifigant change in the lever or perch assembly to throw your adjustment off that far. second, your cable may have frayed or just broke. follow the clutch cable all the way to the engine, and keep an eye on the arm that it attatches to. it should move when you pull the lever. if theres no movement, then your cables broken or frayed. if you can see that the cable is pulling on that arm, then your problem may be internal. also less likely though. but as a last resort, if you have the mechanical knowledge, then check behind the pressure plate for anything that may have broken in the assembly that pushes the pressure plate outwards. IM not too familiar with the kawasaki's design, but there may also be an adjustment screw and locknut right in the center of the pressure plate. tightening up just a little usually solves this isssue.