6-8 CLUTCH
Clutch Cover
Clutch• Cover Removal
Remove:
Engine Oil (drain, see Engine Lubrication System in the Periodic Maintenance 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]
Clutch• Cover Installation
Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket.
•Sealant - Kawasaki Bond (Silicone Sealant): 56019–120
•Replace the clutch cover gasket with a new one. Tighten the clutch cover mounting bolts.
Torque - Clutch Cover Mounting Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)
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 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 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.
CAUTION
When inserting the release shaft, be careful not to remove the spring of the oil seal.
CLUTCH 6-9
Clutch Cover
•Fit the spring [A] as shown. Viewed from Rear [B] Release Shaft [C]
Clutch Cover [D]
Clutch• Cover Disassembly
Remove:
Oil Seal [A]
Needle Bearings
•Remove:
Circlip [A]
Oil Level Gauge [B]
Clutch• Cover Assembly
Replace the needle bearings and oil seal with new ones.
NOTE
○Install the needle bearings so that the manufacture’s
•Install the needle bearings [A] and oil seal [B] position as shown.
Press the bearing until the bottom [C].
Press the bearing so that the bearing surface [D] is flush with the housing end of clutch cover [E].
•Apply water to the rubber of the oil gauge [A] and press it
•so that the projections [B] face inside.
Install a new circlip so that the circlip ends [C] do not warp over the projection [D].mark face out.
6-10 CLUTCH
Clutch
Clutch• Removal
Remove:
Engine Oil (drain, see Engine Lubrication System 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], spring and washer)
•Remove:Friction Plates, Steel Plates
Spring, Spring Seat
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
•Using the two 4 mm (0.16 in.) screws [A], pull out the
•sleeve [B], needle bearing [C] and clutch housing [D]. Remove the spacer.
Clutch• Installation
Install the following parts on the drive shaft.
Spacer [A]
Needle Bearing [B]
Sleeve [C]
Clutch Housing [D]
Spacer [E]
Clutch Hub [F]
Washer [G]
Nut [H]
CLUTCH 6-11
Clutch
○Install the spacer [A] so that the tapered side [B] faces inward.
○Install the washer [A] so that the OUTSIDE mark 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: 135 N·m (14 kgf·m, 100 ft·lb)
•Install the spring seat [A] and spring [B] as shown. Clutch Hub [C]
•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.
○Install the last friction plate [A] fitting the tangs in the grooves in the housing as shown.