Gen 4: 2011-2015 Clutch Replacement - Kawasaki
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post #1 of 3 Old 06-10-2013, 05:39 PM Thread Starter
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Clutch Replacement

I managed to cook my clutch at the last race meeting - so I got myself a new set of fibre and steel plates, springs as well as the clutch cover gasket.

I have read some how-to's and think I can get this done on my own.

Anybody got some other advise maybe - like something I need to look out for etc??

Oh yes - and what about that gasket - does it go in "dry" or do I need to cover it with a sealant?

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post #2 of 3 Old 06-10-2013, 07:21 PM
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I'm about to do a how to thread. You don't need to drop the oil if bike is on side stand but might aswell change it.
Undo the cable, undo the clutch cover bolts, turn the lever on the clutch cover 180 degs and it will just pop off. You didn't really need to buy the steel plates, the fibres wear out first.
Soak the fibres over night and install them in the same order you took them out.
Just look in the workshop manual on how the spacers face and torque settings etc.
Sealant is not really required, it says to put a small amount of sealant in the case joins but I didn't bother, seals good.
Putting the cover on can be a pain, u need to perfectly line up the dowels.
Also, the first major mistake while these slip is because of incorrect clutch adjustment.
Make sure u have a tiny amount of slack when the clutch is HOT.
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post #3 of 3 Old 06-11-2013, 12:44 PM
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Cooked your clutch how? Smeared off the fibers on the friction plates? Burned or warped the steels? If you smeared off the fibers, you need to change the oil, and check it for clutch fiber in the oil. If there is material in the oil, it is a good idea to pull the oil pan and clean the pickup as well.

If all you have to do is change the pack out, Joel explained it well. When putting the clutch cover back on, just make sure the dowels are lined up. It can be a pain sometimes, especially if you are changing it while all the components are hot. (i.e. at the track). I pull my clutch apart weekly, and re-use the same gasket, never having to use sealant, and I have never had a leak. Just take care when removing it all, especially the release shaft as there are two oil seals inside the cover that can be knocked out if you are not careful. Lastly, pay attention to the torque specs on the clutch spring bolts when you are tightening them. You don't have to be Hercules on them, and if you do, you will break off the bolts in the hub. Seen plenty of people do that on their first time.

Last edited by matt d; 06-11-2013 at 12:47 PM.
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