The motorcycle is equipped with a hydraulically operated clutch that requires no adjustment except fluid level inspection and clutch lever position.
A. Clutch Lever
B. Locknut
C. Adjuster
WARNING
Air in the clutch lines diminishes clutch performance and can cause an accident resulting in injury or death. If the clutch lever feels mushy when it is applied, there might be air in the clutch lines or the clutch may be defective. Has the clutch been checked immediately by an authorized Kawasaki dealer?
Clutch Fluid
NOTICE
A. Clutch Fluid Reservoir
B. Upper-Level Line
WARNING
Mixing brands and types of hydraulic fluid can reduce the clutch system’s effectiveness and cause an accident resulting in injury or death. Do not mix two brands of hydraulic fluid. Change the hydraulic fluid in the clutch line completely if the hydraulic fluid must be refilled but the type and brand of the hydraulic fluid that is already in the reservoir are unidentified.
Friction and Steel Plates Removal
A. Brake Pedal Bolt
B. Brake Peda
C. Return Spring
A. Clutch Cover Bolts
B. Clutch Cover
A. Clutch Spring Bolts
B. Holders
C. Stopper Plate
D. Clutch Spring
E. Clutch Pressure Plate
NOTE
Do not loosen each clutch spring bolt separately to prevent the stopper plate warpage.
A. Washer
B. Needle Bearing
C. Push Rod Holder
D. Push Rod
NOTE
Do not remove the push rod. If the push rod is removed, clean the clutch slave cylinder and replace the O-rings of the clutch slave cylinder. Clutch slave cylinder disassembly should be serviced by referring to the Service Manual or an authorized Kawasaki dealer.
NOTE
There are 3 different friction plates installed in the clutch plate assembly
A. Clutch Hub Nut
B. Clutch Holder (Special Tool: 57001-1900)
C. Spacer
D. Clutch Hub
Friction and Steel Plates Wear/Damage Inspection
Friction plate B and C
Friction plate D
A. Thickness
B. Friction Plate
Measure the clutch plate assembly length. When measuring the clutch plate assembly length, assemble the clutch plate assembly (clutch hub, spring seat, spring, friction plates, steel plates, clutch pressure plate, clutch spring, stopper plate, holders, clutch spring bolts).
Tightening Torque
A. Clutch Hub
B. Friction Plate (Identification paint color: Pink)
C. Friction Plate (identification paint color: Green)
D. Friction Plate (identification paint color: Blue)
E. Steel Plates
F. Clutch Pressure Plate
G. Clutch Spring
H. Stopper Plate
L. Standard Length
J. Clutch Spring Bolts
K. Holders
Clutch Plate Assembly Measurement
NOTE
Do not use the steel plate of 2.0 mm (0.079 in.) and 1.4mm (0.055 in.) thickness at the same time.
Friction and Steel Plate Warp Inspection
Place each friction plate and steel plate on a surface plate, and measure the amount of friction plate and steel plate warp with a thickness gauge (i.e., the gap between the surface plate and each friction plate or steel plate).
If any plate is warped over the service limit, replace it with a new one.
Friction and Steel Plate Warp
A. Surface Plate
B. Friction or Steel Plate
C. Thickness Gauge
A. Spacer
B. “OUTSIDE”
Tightening Torque
A. Friction Plate (identification paint color: Blue)
B. Friction Plate (identification paint color: Green)
C. Friction Plate (identification paint color: Pink)
D. Steel Plates
NOTICE
If dry steel plates and friction plates are installed, apply engine oil to the surfaces of each plate to avoid clutch plate seizure.
A. Apply molybdenum disulfide grease.
B. Push Rod Holder
C. Needle Bearing
D. Washer
If the holders are damaged, replace it.
NOTE
Do not tighten each clutch spring bolt separately to prevent the stopper plate from warpage.
A. Clutch Cover
B. O-ring
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