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I have a 1978 Kawasaki KZ650, and I'm trying to install a new clutch cable.

I have been following the removal steps in the Clymer repair manual, but have run into a problem. Here are the steps that I have completed so far:

1. At the center adjuster, loosen the locknut and screw both parts of the adjuster together to allow the maximum amount of cable slack.

2. Loosen the locknut and adjusting nut at the clutch lever and remove the cable from it.

3. Shift the transmission into neutral.

4. Remove the left-hand footpeg and gearshift lever.

5. Remove the 2 bolts securing the starter motor cover and remove it.

6. Remove the 4 bolts securing the engine sprocket cover and remove it.

Here is where I have the problem. After removing the 4 bolts securing the engine sprocket cover, the cover will not come off. I cannot see anything that would prevent this cover from easily being pulled off. While investigating, the cable tip disengaged from the clutch lever, and cable is now removed from the bike.

Any suggestions on what might be preventing the engine sprocket cover from being removed?

Have you tapped, ever so gently, with a rubber or rawhide mallet? More important, could you install that end of the cable without removing the cover?

pictures are worth 1000 words. my cover has a small clip on the backside of it along with being held on with a bolt (yes 1 bolt) so maybe there is a clip somewhere you didnt see or think of. Other than that screwdrivers work good as prybars lol.

*note I am not responsible for broken tools are body parts from not using the correct tool for the job.

I'm unable to attach the new cable to the clutch lever without removing the engine sprocket cover. I'll try looking again for any clip that might be holding it on, and failing that I'll be somewhat "forceful" in attempting to get this cover off. I'll post my results.

On some of my Hondas, the cover has two steel positioning pins on the cover. The steel tends to corrode over time. making it difficult to remove. You also may have that situation..

It's most likely just hanging on by the dowel pins (as stated above). A little gentle persuasion with a rubber mallet and it will come off.

Thanks for all the responses. I went out and used the hammer creatively to dislodge the cover from the bottom right corner. Upon removing the cover I found a lot of built up dirt & gunk that was making this task so difficult. Now on to adjusting the clutch cable!

Mountain Rider wrote:Thanks for all the responses. I went out and used the hammer creatively to dislodge the cover from the bottom right corner. Upon removing the cover I found a lot of built up dirt & gunk that was making this task so difficult. Now on to adjusting the clutch cable!

sweet. Thats one reason I clean all covers/parts I plan on reusing whenever I replace/fix something. Makes it so the next time my work isnt "Doubled".

It doesn't hurt to pull that cover off on occasion and clean the dirt. If anything it'll prevent dirt from wearing the chain and sprocket out.