very stiff clutch lever pull

Here's my clutch cable routing

And another one. Kz750

 

Hi,  did you also check the push Rod?   
On my Z1 i use this z650 lever, see pic, works great

   
On the other side of the push Rod i use this from Ape. I also drive for 40 years with heavy duty springs and its my second clutch cable. So your problem is maybe not only your clutch cable

What am i looking for with the pushrod?

Is the helix style actuator compatible with the KZ700 sprocket cover?

KeylAmi! wrote:

What am i looking for with the pushrod?

Is the helix style actuator compatible with the KZ700 sprocket cover?

The three ball ramp version mechanism replaced the helix version.  Just my opinion, but I chose the three ball over the helix for my 750.

I fitted the ball bearing actuator and the APE pusher to my Z1 and they work great. They didn't necessarily make the lever pull any easier but the clutch engagement is smoother than before.

What am i looking for with the pushrod?


Well it could be damaged or worn out at the top/end.

Most of the (some are made of Aluminum) clutch push rods are worn out at the oil seal area.
I made my own push rods out of high grad stainless steel.

 
 
 
 

I read some where that under hard de-celleration (Drag Race) the rod ends can friction weld and shere of.....

Had that happen twice. Cracked two sprocket covers in a short time. I now have the 650 actuator as shown and the needle bearing pusher as shown. I have Barnett springs and an extra plate and it still is easier than the OEM worm drive. I hated it.
I even added a 1/4" extension to the arm that helped but still broke cables. Had the easy pull style on my Honda but sometimes I'd hear that dreaded pop and no clutch at all. All better now. 
Steve

I was out and about this morning on my 750 and noted that I can pull in the clutch lever easily using just the first two fingers on the left hand.  No big deal.

I keep thinking your issue will turn out to be something simple. Here's another photo I had in the archives and which I should have posted with the one above. Might be worth checking out as its easy enough to get things ass backwards