Clutch Cover Removal
- Drain the engine oil (See Engine Oil Change in the Periodic Maintenance chapter).
Remove:
- Right Rear Frame Cover (See Rear Frame Cover Removal in the Frame chapter)
- Right Lower Fairing (See Lower Fairing Removal in the Frame chapter)
- Clutch Cable Lower End [A] (See Clutch Cable Removal) Clutch Cover Mounting Bolts [B]
![](https://motoinstruction.ru/img/kawasaki/23/128551.jpg)
- Turn the release lever [A] toward the rear as shown, and remove the clutch cover [B].
- About 90° [C]
![](https://motoinstruction.ru/img/kawasaki/23/128552.jpg)
Clutch Cover Installation
- Apply silicone sealant to the areas [A] where the mating surface of the crankcase touches the clutch cover gasket and to the crankshaft sensor lead grommet [B].
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
- Be sure that the dowel pins [C] are in position.
- Replace the clutch cover gasket with a new one.
- Tighten the clutch cover mounting bolts.
Torque - Clutch Cover Mounting Bolts: 9.8 №m (1.0 kgf·m, 87 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128553.jpg)
Release Shaft Removal
Caution: Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required.
- Remove the clutch cover (See Clutch Cover Removal).
- Pull the lever and shaft assembly [A] straight out of the clutch cover.
![](https://motoinstruction.ru/img/kawasaki/23/128554.jpg)
Release Shaft Installation
- Apply high-temperature grease to the oil seal lips on the upper ridge of the clutch cover.
- Apply engine oil to the needle bearings in the hole of the clutch cover.
- Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft.
- Install the washer [B] and spring [C].
- Insert the release shaft straight into the upper hole of the clutch cover.
![](https://motoinstruction.ru/img/kawasaki/23/128555.jpg)
Caution: When inserting the release shaft, be careful not to remove the spring of the oil seal.
- Fit the spring [A] as shown.
- Release Shaft [B]
- Clutch Cover [C]
![](https://motoinstruction.ru/img/kawasaki/23/128556.jpg)
Clutch Cover Disassembly
Remove:
- Clutch Cover (See Clutch Cover Removal)
- Release Leer and Shaft Assembly (See Release Shaft Removal)
- Oil Seal [A]
- Needle Bearings [B]
![](https://motoinstruction.ru/img/kawasaki/23/128557.jpg)
Remove:
- Oil Level Gauge [A]
- Timing Inspection Cap [B]
- Timing Rotor Bolt Cap [C] Oil Filler Plug [D]
![](https://motoinstruction.ru/img/kawasaki/23/128558.jpg)
Clutch Cover Assembly
- Replace the needle bearings and oil seal with new ones.
Note: lnstall the needle bearings so that the manufacture's mark face out.
- Install the needle bearings [A] and oil seal [B] position as shown.
Press [C] the bearing so that the bearing surface [D] is flush with the housing end of clutch cover [E].
![](https://motoinstruction.ru/img/kawasaki/23/128559.jpg)
- Apply water to the rubber of the oil gauge [A] and press [B] it so that the ring [C] face outside.
- Replace the O-rings of the following parts with new ones.
- Timing Inspection Cap
- Timing Rotor Bolt Cap
- Oil Filler Plug
- Apply grease to the new O-rings.
Tighten:
Torque - Timing Inspection Cap: 3.9 Nm (0.40 kgf·m, 35 in·lb)
Timing Rotor Bolt Cap: 4.9 Nm (0.50 kgf·m 43 in·lb)
Oil Filler Plug: Hand-tighten
![](https://motoinstruction.ru/img/kawasaki/23/128560.jpg)