![background image](/i/kawasaki/160046/kawasaki-er5-2004/h/kawasaki-er5-2004-115.png)
CLUTCH 5-5
Clutch Lever and Cable
Due to friction plate wear and clutch cable stretch over
a long period of use, the clutch must be adjusted in accor-
dance with the Periodic Maintenance Chart.
WARNING
To avoid a serious burn, never touch the engine or
exhaust pipe during clutch adjustment.
Clutch Adjustment
Clutch Lever Free Play Inspection
•
Pull the clutch lever just enough to take up the free play
[A].
•
Measure the gap between the lever and the lever holder.
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust the clutch.
Clutch Lever Free Play
Standard:
2
∼
3 mm (0.08
∼
0.12 in.)
Clutch Lever Free Play Adjustment
•
Slide back the dust cover [A].
•
Loosen both adjuster nuts [B] at the right hand crankcase
as far as they will go.
•
Loosen the knurled locknut [A] at the clutch lever.
•
Turn the adjuster [B] so that 5
∼
6 mm (0.20
∼
0.24 in.) [C]
of threads are visible.
WARNING
Be sure that the outer cable end at the clutch lever
is fully seated in the adjuster at the clutch lever, or
it could slip into the place later, creating enough
cable play to prevent clutch disengagement.
•
After the adjustment is made, start the engine and check
that the clutch does not slip and that it releases properly.
Clutch Lever Installation
•
Install the clutch lever so that the mating surface [A] of
the lever holder is aligned with the punch mark [B] on the
handlebar.