- 10mm socket wrench
- Phillips head screwdriver
- Flat-head screwdriver
Procedure
Follow the steps below to adjust the clutch on your Kawasaki KE100:
1. Preparation:
- Park your motorcycle and turn off the engine.
- Let the motorcycle cool down if it's been recently ridden.
- Place the motorcycle on a center stand or lift the rear wheel off the ground.
2. Locate the Clutch Cable:
- The clutch cable is the primary component you need to adjust.
- It's usually located on the left side of your handlebars, near the clutch lever.
3. Inspect the Clutch Cable:
- Check the condition of the clutch cable. Ensure that it is properly routed and not frayed, kinked, or broken.
4. Loosen the Adjusting Nut:
- At the end of the clutch cable, where it attaches to the clutch lever, there is an adjusting nut.
- Locate this lock nut and use the 10mm socket wrench to loosen it.
5. Adjust the Clutch Lever Free Play:
- The free play of the clutch lever is the distance you can move the lever before it starts engaging the clutch.
- Kawasaki KE100s have a recommended clutch lever free play of 3mm - 5mm (0.12 - 0.2 inches).
- Turn the adjusting nut to increase or decrease the free play at the clutch lever.
- To increase free play: turn the nut clockwise.
- To decrease free play: turn the nut counterclockwise.
6. Check the Clutch Lever Engagement:
- Once you've set the desired free play, check how the clutch engages. Test it by pulling the clutch lever in while shifting through gears.
- The clutch should engage smoothly, without any slipping or grinding noises.
- If you feel any issues while engaging the clutch, fine-tune the adjustment to achieve a smooth engagement.
7. Tighten the Adjusting Nut:
- After achieving the correct clutch lever free play and smooth clutch engagement, tighten the adjusting nut using the 10mm socket wrench.
8. Secure the Clutch Cable:
- Ensure the clutch cable is securely routed and fastened. You can use the Phillips head screwdriver to tighten any loosened nuts or bolts along its length if necessary.
9. Test Ride and Fine Adjustments:
- Take your motorcycle for a test ride to assess the clutch adjustment. Test it in various riding conditions, including idling, shifting, and stopping.
- If needed, make further minor adjustments to the clutch lever free play until you're satisfied with its performance.
Remember, proper clutch adjustment is essential for the smooth operation of the motorcycle. If you feel uncertain about the process or encounter any issues during the adjustment, it's best to consult a qualified motorcycle mechanic or refer to your motorcycle's specific service manual for detailed instructions.
