Clutch Lever and Cable

Clutch Lever Installation

_• Install the clutch lever so that the mating surface [B] of the clutch lever clamp is aligned with the punch mark [A].

_• Tighten the upper clamp bolt first, and then the lower

clamp bolt. There will be a gap at the lower part of the

clamp after tightening.

Torque - Clutch Lever Clamp Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Clutch Lever Adjustment

The adjuster has 5 positions so that the clutch lever posi- tion can be adjusted to suit the operator’s hand.

_• Push the lever forward and turn the adjuster [A] to align

the number with the arrow mark [B] on the lever holder.

○^{The distance from the grip to the lever is minimum at num-}

ber 5 and maximum at number 1.

Clutch Cover Removal

_• Remove:

Engine Oil (Drain, see Engine Oil Change in the Periodic

Maintenance chapter)

Right Frame Cover (see Frame Cover Removal in the Frame chapter)

Right Center Fairing (see Center Fairing Removal in the Frame chapter)

Clutch Cable Lower End [A] Clutch Cover Mounting Bolts [B]

_• Turn the release lever [A] toward the rear as shown, and remove the clutch cover [B].

About 90° [C]

_• Push the release lever toward the front of the motorcycle and tape the release lever to the clutch cover to prevent

the release shaft from falling out.

Clutch Cover Installation

_• Apply silicone sealant to the area [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 [D] with a new one.

_• Tighten the clutch cover mounting bolts.

Torque - Clutch Cover Mounting Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

Clutch Cover

Release Shaft Removal

_• Remove the clutch cover (see Clutch Cover Removal).

_• Pull the lever and shaft assembly straight out of the clutch

cover.

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.

_• Fit the spring [A] as shown. Release Shaft [B]

Clutch Cover [C]

Clutch Cover Disassembly

_• Remove:

Oil Seal [A]

Needle Bearings [B]

_• Remove the oil level gauge [A].

Clutch Cover Assembly

_• Replace the needle bearings and oil seal with new ones.

NOTE

○^{Install 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 flushwith the housing end of clutch cover [E].

_• Apply water to the rubber of the oil gauge [A] and press [B] it so that the ring [C] face outside.

Clutch Removal

_• Remove:

Engine Oil (Drain, see Engine Oil Change in the Periodic

Maintenance chapter)

Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A]

Clutch Springs

Clutch Spring Plate [B] (with thrust bearing and pusher [C])

_• Remove:

Friction Plates, Steel Plates

Clutch Hub Nut [A]

○^{Holding the clutch hub [B], remove the nut and washer.}

Special Tool - Clutch Holder [C]: 57001-1243

_• Remove: Clutch Hub

Spacer

_• Remove the oil pump sprocket bolt [A].

NOTE

○^{The oil pump sprocket bolt has a left-hand threads.}

_• Using the hole [B], pull out the sleeve [C].

_• Remove the following as a set.

Clutch Housing [D]

Oil Pump Chain [E] Oil Pump Sprocket [F]

_• Unscrew the bolts [A] and remove the oil pump chain guide [B].

Clutch Installation

_• Apply a non-permanent locking agent to the oil pump chain guide bolts and tighten them.

Torque - Oil Pump Chain Guide Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

_• Put the oil pump chain [A] on the clutch housing gear [B]

and the oil pump sprocket [C].

_• Be sure that the spacer [A] is in position.

_• Insert the following on the drive shaft.

Clutch Housing [A] with Chain [B] and Sprocket [C]

Sleeve [D]

_• Align [E] the hole on the oil pump sprocket with the oil pump shaft.

NOTE

○^{Insert the sleeve into the clutch housing, noting its di-}

rection as shown.

Sleeve [A] Oil Holes [B]

Long Distance [C] Short Distance [D] Clutch Housing [E]

_• Install the following parts on the drive shaft. Spacer [A]

Clutch Hub [B] Washer [C] Nut [D]

○^{Install the washer so that the OUTSIDE mark [A] faces} outward.

○^{Replace the clutch hub nut with a new one.}

○^{Holding the clutch hub, tighten the clutch hub nut.}

Special Tool - Clutch Holder: 57001-1243

Torque - Clutch Hub Nut: 132 N·m (13.5 kgf·m, 98 ft·lb)

_• Install the friction plates and steel plates, starting with a friction plate and alternating them.

○^{For the first steel plate [A], its thickness is 2.6 mm (0.10} in.). The others are 2.3 mm (0.09 in.).

○^{Install the last friction plate [A] fitting the tangs in the} grooves in the housing as shown.

_• Apply molybdenum disulfide grease to the pusher ends [A] and install it in the clutch spring plate [B].

○^{Apply engine oil to the bearing [C].}

_• Install the clutch spring plate and springs [D], and tighten the clutch spring bolts [E].

Torque - Clutch Spring Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

_• Install the clutch cover (see Clutch Cover Installation).

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.)

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 and Steel Plate Warp

Standard: 0.15 mm (0.006 in.) or less Service Limit: 0.3 mm (0.012 in.)

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.)

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.

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.