Clutch release problem

[MotoV4]

This is going to be a tricky one to explain. My 82 Z1000J has lost the use of its clutch. I pulled in the lever to start it and suddenly it went slack. the cable is intact but it looks like the clutch release has flipped over. In the workshop manual it is shown as holding the cable at the bottom but mine now has the cable at the top, like it has flipped over somehow. i took the cable off and moved the clutch release lever to the bottom and tested it a few times on the third pull it flipped over again. Anyone else come across this ? Kind of hoping it turns out to be one of those common problems with a quick fix. Cheers

[Ginger Bear]

I had a similar problem with my Unitrak. I found that a 'bit more slack' in the cable helped. Having it adjusted without any slack lets it travel too far & lets the actuator arm 'pop' out of it's housing.
I'm sure someone will tell us a better way to do it, with the adjuster on the casing.

[z1bman]

make sure you have plenty of slack in the cable. turn the middle cable adjuster fully to its minimum adjustment. then adjust the cable at the clutch lever ( handlebar) so the adjuster is about 10mm out. then set your clutch release lever in the correct position. the lever arm should be in the 8 o clock position looking at it from the back of the cover. replace the cover slacken the clutch release lock nut . unscrew the adjuster bolt + then turn back in until you feel some resistance. at this point turn it back half a turn in the opposite direction tighten the lock nut then put the required free play in the lever by adjusting the middle cable adjuster

[Al]

As above plus; there is a flat cut off the side of the plate which holds the 3 bearings. Need to make sure it is indexed with the peg inside the housing. If it isnt the datum start point is half way through the adjustment range and you'll spend weeks fiddling inside the clutch.
From memory the adjuster screw under the rectanguler out cover is counter intuitive in its action. The above only applies if you dont have the helical spiral type of actuator.


AL

[MotoV4]

Thanks for the responses I will check the cable, I have a new one coming so will aim to set it up as you described. I did adjust it before this happened so there is a possible cause there. I slacked the cable at the lever end as it was out a fair way and took up the slack on the barrel adjuster lower down on the frame. I will also check to see if mine is one of the spiral type actuators ( I think it is). Cheers