Clutch replacement?

My clutch is original with 49k on it. Has always been adult ridden (no burouts, wheelies, etc) and the clutch seems fine, no slippage at all but I have noticed that while cruising down the road if I just barely pull in the lever the RPM's shoot up. Other than that the clutch works fine, is this fairly normal? And if it is clutch time (have new metal @ fiber plates, springs)) is it as easy as pulling the cover, removing the 5 bolt plate and swapping plates and springs (leaving clutch basket on bike) and reinstalling cover (new gasket of course)? Don't want bike down now as BIG ride this Saturday! Thanks guys...

while cruising down the road if I just barely pull in the lever the RPM's shoot up.

If you are on the gas, going down the road and barely pull in the clutch lever, you bet the RPM will shoot up.

I did the clutch adjustment first but, the clutch started slipping when I would be in 4th or 5th gear and I got on it.
Just like you said, pull cover and replace plates and springs. I didn't have to replace my steel plates [just did the checking of being warped or not and scuffing/cleaning them a little w/a green pad (not as rough as steel wool)]. My basket looked fine.
I went w/the "Roller clutch push rod kit" (even though mine didn't show any abnormal wear, just like the idea of bearings taking this load instead of just a plate) and the APE Extra-disk Heavy Duty clutch pack, but I used my original springs since my Baby didn't have over 20K on it (I didn't want the extra pull required that some say these "heave duty springs" give you).
Here is Z1Enterprises link to your model

Post edited by: ejshotgun, at: 2007/04/24 10:36

I'd say your clutch is fine. If you do replace anything, all that should be needed is friction plates. I don't know how the ape kit is, but if it's standard "racing" stuff it would mean the springs are way too stiff and do you no good other than meaning extra wear and tear on your cable and clutch release mech ect. All the miles I've ridden a KZ I never replaced a clutch plate yet on any of my KZs. I did put a Barnett racing clutch in the H2 and had the wonderful experience of that stiff lever and the plates disintegrated in about 1000 miles, so back to stock plates in that one.

Post edited by: RonKZ650, at: 2007/04/24 12:39

To answer the rest of your question. It is fairly easy to change out the plates and springs. If you still have the phillips head screws holding the clutch cover on, you might want to have an impact driver handy.

Are You SURE that the cable is adjusted properly?:huh:
Is there enough free-play,and did You adjust it right at the clutch cover,on the left side of the engine?(snug the screw,and then back it off a quarter turn approx.,and make sure You hold the screw with a screwdriver,while You tighten the locknut)...

Providing you have the needed tools, all parts requiring replacement, AND none of the clutch cover screws become stripped while removing them, it's basically less than an hour job from start to finish - and that's including changing the oil and filter.


FWIW my 650 does the same thing, and I'm certain that my clutch plates and springs are still good.
Most times a worn clutch will make itself noticeable by slipping when "goosing" the trottle while in 4th and/or 5th gear.

Double check all the adjustments too like Sandy said. Always go with a Kawasaki clutch and not that barnett crap. My buddy uses Kawi' plates in his drag bike. Most times the springs are fine. Like R4 said overall it's a easy job.
Mark

I have an APE kit in my bike and I like it. my old one was slipping bad in the upper gears. the heavier springs arent an issue, but you know they are in there in stop and go traffic:P I may try swapping in a couple old springs for something inbetween if I find myself doing a lot more city driving and it actually starts to bother me, but i doubt that will happen

I got the plates and springs from Z1, so they should be comparable to OEM. Thanks guys, it does NOT slip in 4th or 5th so guess I'm ok for now. Will put parts on shelf until needed. I do follow the factory manual on cable adjustment, appreciate the wisdom guys...

If you do plan to do it in the future, this is a good site to bookmark or reference for info befoer you do it.


www.motorcyclecruiser.com/tech/clutch_replacement/