Clutch Removal
Remove:
- Clutch Cover (See Clutch Cover Removal)
- Clutch Spring Bolts [A]
- Clutch Springs
- Clutch Spring Plate [B] (with bearing)
- Pusher [C]
![](https://motoinstruction.ru/img/kawasaki/23/128561.jpg)
Remove:
- Friction Plates
- Steel Plates
- Hold the clutch hub [A] steady with the clutch holder [B], and remove the clutch hub nut [C] and washer [D].
Special Tool - Clutch Holder: 57001-1243
![](https://motoinstruction.ru/img/kawasaki/23/128562.jpg)
Remove:
- Clutch Hub [A]
- Spacer [B]
![](https://motoinstruction.ru/img/kawasaki/23/128563.jpg)
- Remove the oil pump sprocket bolt [A].
Note: The oil pump sprocket bolt has a left-hand threads.
- Using the holes [B], pull out the sleeve [C].
- Remove the following as a set.
- Clutch Housing [D]
- Oil Pump Chain [E]
- Oil Pump Sprocket [F]
![](https://motoinstruction.ru/img/kawasaki/23/128564.jpg)
Remove:
- Bolts [A]
- Oil Pump Chain Guide [B]
- Spacer [C]
![](https://motoinstruction.ru/img/kawasaki/23/128565.jpg)
Clutch Installation
- Engage the oil pump chain guide [A] to the groove of the shift rod [B], and apply a non-permanent locking agent to the upper chain guide bolt [C] and tighten the chain guide bolts.
Torque-Oil Pump Chain Guide Bolts: 12 Nm (1.2 kgf·m, 106 in·lb)
- Install the spacer [D] on the drive shaft.
![](https://motoinstruction.ru/img/kawasaki/23/128566.jpg)
- Put the oil pump chain [A] on the clutch housing gear [B] and the oil pump sprocket [C].
![](https://motoinstruction.ru/img/kawasaki/23/128567.jpg)
- Install the following on the drive shaft as a set.
- Clutch Housing [A]
- Oil Pump Chain [B]
- Oil Pump Sprocket [C]
- Install the sleeve [D] so that the holes [E] faces outward.
Apply engine oil to the sleeve.
- Align the hole on the oil pump sprocket with the oil pump shaft.
- Apply a non-permanent locking agent to the oil pump sprocket bolt [F] and install the washer.
Tighten:
Torque - Oil Pump Sprocket Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
Note: The oil pump sprocket bolt has a left-hand threads.
![](https://motoinstruction.ru/img/kawasaki/23/128568.jpg)
- Install the following parts on the drive shaft.
- Spacer [A]
- Clutch Hub [B]
![](https://motoinstruction.ru/img/kawasaki/23/128569.jpg)
- Install the washer so that the OUT SIDE mark [A] faces outward.
![](https://motoinstruction.ru/img/kawasaki/23/128570.jpg)
- Replace the clutch hub nut [A] with a new one.
- Hold the clutch hub [B] steady with the clutch holder [C], and tighten the clutch hub nut.
Special Tool - Clutch Holder: 57001-1243
Torque - Clutch Hub Nut: 130 Nm (13.3 kgf·m 96 ft·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128571.jpg)
- Install the friction plates and steel plates, starting with a friction plate and alternating them.
Caution: If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each plate to avoid clutch plate seizure.
For the first steel plate [A], its thickness is 2.6 mm (0.10 in.). The others are 2.3 mm (0.09 in.).
![](https://motoinstruction.ru/img/kawasaki/23/128572.jpg)
Install the last friction plate [A] fitting the tangs in the grooves in the housing as shown.
![](https://motoinstruction.ru/img/kawasaki/23/128573.jpg)
- Apply molybdenum disulfide grease to the pusher end [A].
- Install the pusher[B] to the drive shaft direction as shown
![](https://motoinstruction.ru/img/kawasaki/23/128574.jpg)
- Apply engine oil to the sliding surfaces of the bearing [A].
- Install the spring plate [B] on the clutch hub [C].
- Install the clutch springs, and tighten the clutch spring bolts.
Torque - Clutch Spring Bolts: 9.8 Nm (1.0 kgf·m, 87 in·lb)
- Install the clutch cover (See Clutch Cover Installation).
![](https://motoinstruction.ru/img/kawasaki/23/128575.jpg)
Clutch Plate, Wear, Damage Inspection
- Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear.
- Measure the thickness of each friction plate [A] at several points.
If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.
Friction Plate Thickness
Standard: 2.92-3.08 mm (0.115-0.121 in.)
Service Limit: 2.8 mm (0.110 in.)
![](https://motoinstruction.ru/img/kawasaki/23/128576.jpg)
Clutch Plate Warp Inspection
- Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with a new one.
Friction Plate Warp
Standard: 0.15 mm (0.006 in.) or less
Service Limit: 0.3 mm (0.012 in.)
Steel Plate Warp
Standard: 0.2 mm (0.008 in.) or less
Service Limit: 0.3 mm (0.012 in.)
![](https://motoinstruction.ru/img/kawasaki/23/128577.jpg)
Clutch Spring Free Length Measurement
- Measure the free length of the clutch springs [A].
If any spring is shorter than the service limit, it must be replaced.
Clutch Spring Free Length
Standard:33.6 mm (1.32 in.)
Service Limit: 32.6 mm (1.28 in.)
![](https://motoinstruction.ru/img/kawasaki/23/128578.jpg)
Clutch Housing Finger Inspection
- Visually inspect the clutch housing fingers [A] where the friction plate tangs [B] hit them.
If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged.
![](https://motoinstruction.ru/img/kawasaki/23/128579.jpg)
Clutch Housing Spline Inspection
- Visually inspect where the teeth [A] on the steel plates wear against the clutch hub splines [B].
If there are notches worn into the splines, replace the clutch hub. Also, replace the steel plates if their teeth are damaged.
![](https://motoinstruction.ru/img/kawasaki/23/128580.jpg)