CLUTCH 6-7

Clutch Cover

Clutch Cover Removal

•Remove the bolt [A].

•Remove the cover [B] from the frame.

•Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter).

•Remove:

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

Clutch Cable Lower End [A] (see Cable Removal) Clutch Cover Bolts [B]

Bracket [C]

•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): 92104-0004

•Be sure that the dowel pins [B] are in position.

•Replace the clutch cover gasket with a new one.

•Install the bracket [A].

•Tighten:

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

L = 40 mm (1.57 in.) [B]

L = 25 mm (0.98 in.) [C]

6-8 CLUTCH

Clutch Cover

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 release lever and shaft assembly [A] straight out of the clutch cover.

Release Shaft Installation

•Apply 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.

CAUTION

When inserting the release shaft, be careful not to remove the spring of the oil seal.

•Fit the spring [A] as shown in the figure. Rear View [B]

Release Shaft [C]

Clutch Cover [D]

Clutch Cover Disassembly

•Remove:

Clutch Cover (see Clutch Cover Removal)

Release Lever and Shaft Assembly (see Release Shaft Removal)

Oil Seal [A]

Oil Filler Plug [B]

CLUTCH 6-9

Clutch Cover

•Remove: Bolts [A] Plate [B] Pads

Needle Bearings [C] Oil Level Gauge [D]

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 in the figure.

○Apply grease to the oil seal lips.

○Press the lower bearing, do not protrude from the boss [C] of the clutch cover.

○Press the upper bearing so that the bearing surface [D] is flush with the housing end of clutch cover [E].

○Press the oil seal until the bottom.

•Apply water to the rubber portion [A] of the oil level gauge.

•Press the gauge so that its projection [B] faces inside of the clutch cover [C].

•Replace the O-ring [A] of the oil filler plug [B] with a new one.

•Apply grease to the new O-ring.

•Tighten:

Torque - Oil Filler Plug: Hand-tighten

6-10 CLUTCH

Clutch Cover

•Install: Pads [A] Plate [B]

•Apply a non-permanent locking agent to the threads of the clutch cover plate bolts [C], and tighten them.

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