It's easy. Usually needs replacing only if it's slipping, worn by high mileageor if it overheated and warped the plates. That usually happens if you slip the clutch too much during launches or trying to pull up a wheelie. I don't think I have ever had to replace a clutch on my bike except this05 636I just built. The previous owner/ rider had burned it up. There were actually burnt/ overheated spots on the steel plates. I just did this; should have taken pictures!

Anyway, if you have to do it:

Pull up the Parts diagram on the www.kawasaki.com website.

1. Put the bike on the sidestand.
2. Remove the RH mid/ lower fairing.
3. Put a small drain pan (may lose onlya few teaspoons of oil)
4. Remove the clutch cable bracket and disconnect the cable
5. Remove the clutch cover bolts & cover (Loosen first and tap the cover with a mallet to break the gasket seal) Rotate the cover lever counterclockwise to release.
6. Remove the bolts that retain the springs and remove the pressure plate. (Keep track of all the center actuator rod &parts)
7. Remove the Friction & steel plates (Remember the order in whick they were removed including the ring washer & ringspring)
8. Inspect & install the new plates then reverse the order of removalfor re-installation. The pressure plate goes on only one way or 180 the other way. Make sure it's seated properly. Torque the pressure plate bolts.
9. Use a new gasket or apply a thin film of permatex semi drying gasket sealant on the gasket.

Hope that helps.

 

Right on speed, a basic 101 which includes keeping the parts in the correct placement on the counter. Nice

 

May be an old wives tale, but I have always soaked the new plates in oil for an hour or two before I install them. Seems to help with the mating process. (There's a joke in there somewhere, I'm sure...)

 

some companies still require a pre-soak. DP clutches typically doesn't but barnett and EBC do..

i do it regardless.. it doesn't hurt it any.

 

wouldn't hurt to pre-soak everything that normally will be bathed in oil anyways. that way its not all dry the first time you try to use the clutch.

 

nice write up speed!! thanx!