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Friction And Steel Plates Wear Inspection; Friction And Steel Plate Warp Inspection; Spring Free Length Measurement; Friction Plate/clutch Housing Finger Damage - Kawasaki KDX200 Service Manual

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5-14 CLUTCH
.
Tighten:
Torque
-
Clutch
Spring
Bolts:
8.8 N-m
(0.90 kg-m, 78 In.lb)
Clutch Hub
Nul:
88 N-m (9.0
kg-m, 65
ft-Ib)
eApply
molybdenum
disulfide grease to the rubbing portion of
the
clutch
pusher,
Friction
and
Steel Plates Wear Inspection
.
Visually inspect the friction and steel plates
to
see if they show any
signs of seizure, or uneven
wear.
*
If
any
plates show signs of damage, replace
the Iriction
plates and steel
plates as a set.
Measure the thickness 01
the
friction plates
[AJ
with vernier
calipers.
*
If
they
have worn
past
Ihe
service limit, replace
them
wIth new
ones.
Friction Plate Thickness
Standard:
2.92
_
3.08
mm
Servk;e
Limit:
2.70
mm
Friction
and
Steel Plate Warp
Inspection
.
Place each friction
plate
or steel plate [AJ on a surface plate, and
measure
the gap between
t
he surface plate
[C]
and
each friction plate
or steel
plate
with
a
thickness gauge
[8].
The
gap is
the
amount of
frict
ion or
steel
plate
warp.
*
If any
plate
is
warped over
the
service
limit,
replace it with a new one
Frlcllon and Steel Plates Warp
Standard:
0.2
mm
or
leu
Service
limit
0.3 mm
Spring
Free
Length Measurement
e
Since
the
spring
[AJ
becomes shorter as it weakens, check its free
length
to
determ
ine its condition.
*
If any of the springs is shorter than the service limit,
it
must be
replaced.
Clutch Spring Free length
Standard:
38.7 mm
Service
Limit
37.2
mm
Friction
Plate/Clutch
Housing Finger Damage
e
Visually inspect
the
clutch housing fingers
(A]
where the friction plate
tangs hit
them.
*If they
are badly worn or if thare are groove cuts where the tangs hit.
replace the housing.
e
Also,
replace
the friction plates if their
tangs
[8]
are
damaged.
A
A

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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