How To install Clutch Kit - How-Tos and FAQs @ KawiForums.com

http://kawiforums.com/forum/topic.asp?TOPIC_ID=22881

Original post by: kilaman




This was done on a 2001 ZX9R, but can be used on other models.

Tools:
What ever to remove your fairing
10mm socket
5mm allen wrench
oil catch pan
oil

You can do this install with or WITHOUT changing the oil. As long as you have the bike supported by the kickstand you will not loose any oil. But an oil change is strongly recommended.

Before you even start to remove the fairing, go ahead and start soaking the new fiber plates in oil. I have heard different lengths of times of soaking ranging from a minimal of 15 minutes to one hour. If you start soaking now before you do anything else they should be ready by the time you install them on the bike.


Remove fairing, clutch cover, and disconnect the clutch cable from the cover.


Before removing the springs and hub cover, pay close attention to the (red arrow) vs. the (green arow) in the pic. All of the fiber plates line up at the green arrow slot except the very last, or outermost, fiber plate. It fits into the short notched area at the red arrow. TAKE YOUR TIME AND LOOK AT THIS CLOSELY!!!! Plus pay attention to how tightly the hub is to the first fiber plate. You will see later.


Remove the 5 springs holding the hub cover, then CAREFULLY remove the hub cover. There are needle bearings on the inside of the hub cover. BE CAREFUL!!!



Every thing loose.


Remove all plates. Steels (red) Fibers (green)


With all plates removed inspect your clutch basket and hub for wear or cracks.


Reinstall plates starting with the fiber then alternate to steel to fiber to steel etc.


New kevlar fiber plates. Remember about the last fiber plate installed. It goes into the short notch!!! See pic at beginning of thread!!!


Install the heavy duty springs included in the kit and reinstall the hub cover. Installing the hub cover is another WATCHOUT!!!! The hub will install any way but it only FITS ONE WAY!!! You have to keep test fitting the hub cover until it fits FLUSH against the last fiber plate before you put the springs in. Its kinda tricky because it looks like its on but there is actually about 1/8th inch space between the hub cover and the fiber plate. If so pull the hub cover back off, turn to the next holes line up again and put back on until the hub fits flush and there is no play in the plates. If not your clutch will NOT engage and your wheel will not move!!!! Learn from my mistakes!!!!



Reinstall the cover and clutch cable. Adjust your play in you lever correctly, about 1/4 inch. Check for leaks. Test ride before you put your fairings back on. Saves time if something is wrong.

**ALSO** when installing the new steel plates, make sure that they are all installed in the same direction, that is, notice how they are stamped on one side and install them with the sharp side facing outward.
Update by:

melloyello

Kilaman, the easiest way to get the cover to line up the first time is to mark the cover and one of the spring locations after you remove the first spring. This will prevent any confusion anyone may have in reassembly.