Kawasaki Z1000SX - Service manual > Clutch Plate Assembly Inspection

• Inspect the friction plate thickness (see Clutch Plate, Wear, Damage Inspection).
• Measure the length [A] of the clutch plate assembly as shown in the figure.
  • Assemble:
    Clutch Hub [B]
    Spring Seat [C]
    Spring [D]
    Friction Plates [E]
    Steel Plates [F]
    Clutch Spring Plate [G]
    Clutch Springs [H]
    Clutch Spring Bolts [I]

NOTE

• Install the both ends marked two friction plates at disassembled to the their original position.

Torque - Clutch Spring Bolts: 9.0 N*m (0.90 kgf*m, 80 in*lb)

Clutch Plate Assembly Length
 Standard: 51.1 - 51.7 mm (2.01 - 2.04 in.)

If the length is not within the specified range, adjust the length (see Clutch Plate Assembly Adjustment).

Clutch Plate Assembly Adjustment

• Inspect the clutch plate assembly length, and then replace the steel plate(s) which brings the length within the specified range.
• Remove:
  Clutch Spring Bolts
  Clutch Springs
  Clutch Spring Plate
• Replace the following steel plate(s).

NOTE

• Do not use the steel plate of 2.3 mm (0.091 in.) and 2.9 mm (0.114 in.) thickness at the same time.

 

• Install the removed parts, and inspect the clutch plate assembly length.

  Torque - Clutch Spring Bolts: 9.0 N*m (0.90 kgf*m, 80 in*lb)

Clutch Plate, Wear, Damage Inspection

• Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear.
• Measure the thickness of each friction plate [A] at several points.

  If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.

Friction Plate Thickness
 Standard: 2.72 - 2.88 mm (0.107 - 0.113 in.)
 Service Limit: 2.4 mm (0.094 in.)

Clutch Plate Warp Inspection

• Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp.

  If any plate is warped over the service limit, replace it with a new one.

Friction and Steel Plate Warp
 Standard: 0.15 mm (0.0059 in.) or less
 Service Limit: 0.3 mm (0.012 in.)

Clutch Spring Free Length Measurement

• Measure the free length of the clutch springs [A].

  If any spring is shorter than the service limit, it must be replaced.

Clutch Spring Free Length
 Standard: 64.8 mm (2.55 in.)
 Service Limit: 61.8 mm (2.43 in.)

Clutch Housing Finger Inspection

• Visually inspect the clutch housing fingers [A] where the friction plate tangs [B] hit them.

  If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged.

Clutch Housing Spline Inspection

• Visually inspect where the teeth [A] on the steel plates wear against the clutch hub splines [B].

  If there are notches worn into the splines, replace the clutch hub. Also, replace the steel plates if their teeth are damaged.

See also: