Z1OwnersClub GB

Z1R (1978) clutch cable replacement


Hi, guys I'm trying to replace the cluth cable just because it's old and I don't want it brakes during a ride .
As you can guess is the first time that I try this task and soon I got stucked .

This is what I've done following the climer instruction

- Sprocket cover Removal: this is what I've done

1) left front footpeg removed
2) gearshift removed
3) starter motor cover removed
4) 4 bolts mounting the sprocket cover the engine removed

Naturally at this point I aspected the sprocket cover to be simply removed but simply it didn't come out .

I've removed the adjusting cover to give a look inside and once removed what I see is the outern part of the clutch release mechanism and it seems stucked on the sprocket cover .

Just because I don't want to force anything without knowing what I'm doing I stopped my work

What I have to do now ?

please help

If a picture is needed just ask .


thanks in advance !

Fabio

The cover should come off if the bolts and gear lever are removed. Tap it with a rubber mallet & wiggle it about whilst pulling it off.

The cover may have dowels to firmly locate the cover which makes it a tight fit.

You don't need to do anything with the inspection cover.

Thanks Pigford !!!

Tomorrow morning I will try and let you know .

have you loosend the starter motor cover a little,as it bolts down onto the caseing.

Cant add to this however the start motor cover is usually the suspect but if you have lifted this that then its patience and carefull levering and tapping

hillbilly wrote:have you loosend the starter motor cover a little,as it bolts down onto the caseing.

Fabio said he has removed starter cover.
the pigster is probably right it needs tapping with a rubber mallet.

...........failing that, a few choice WORD's always seem to help, along with chucking a few tools around the garage for 5 minutes.....

I've tried tapping but the sprocket cover seems stucked on this two points:



I don't want to be too much strong because usally in this way I broke something ..

I'm starting to think that I could give up, but I have a brand new clutch cable and it's a pity quitting in this way .

Hi Fabio those parts you have arrowed will not stop the cover coming off, the top one adjusts the free play and the bottom one is the gear shaft,

As long as you have taken out the four bolts and the starter motor chrome cover - you have done all you need to do, time to get the rubber mallet on the cover to loosen all the crud off,

Give it a fair tap

Cheers

PJ

Fabio,if you have taken the four bolts off it should just pull off sometimes they are very tight and you may need to use a flat screwdriver to ease it off, just keep trying and it will come off.
good luck Kev.

Ok guys Thanks a lot for the precious informations !!!

I'll give yopu soon news !

there are fixing tubes at the end of the screw holes backwards to keep the cover in place so the first 5 mm you can only move the cover front or backward NOT left and right.
between the inner side of the cover and the crankcase the shifter lever often becomes rusty and full of chain oil sand mix and keeps the cover in place very strong.
would be some easier to make a grip and fix it on the 2 holes for the small egg cover so can push it out easier than grabbeling with the fingers behind the cover.

hope my english is understandable

roll on!
amir

-thanks Z1rII for your hints !!

Your English is very good (from my point of view naturally)

I've got it !!

As you all said a bit of levering has released the sprocket cover




As you can see inside, the sprocket cover was filled of old "sandy" grase .

I've cleaned up the sprocket cover and the sprocket .

Now finishing the job should be quite easy ( touching wood) .
I hope I can count on you if I get stucked again .

I wonder what is that blue wire ...

Thanks very much guys.
You are wonderful!!!

sorry I wrote "sandy" grase

please read "sandy" grease .