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Clutch Installation Notes - Kawasaki KX125 1990 Service Manual

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-
Use
the
clutch
holde
r
(specia
l
tool) to
prevent t
he
clutch
hub
from
rotatin
g.
A.
Clutch Holde
r:
57001-1243
B.
Clutch Hub Nut
-
Remove
the
clutc
h hub nut and
washer.
-
Remove
the
d
utch
assembly, needle
bearing.
sleeve,
and th rust washer.
A.
Needle Bearing
C.
Thrust
Washe
r
B.
Sleeve
Clutch Installation Notes
-
In st
allation
is the reverse
of
removal.
-
Appl
y
molybdenum d
isulfide grease
to the outside
of
the
sleeve.
-
Apply
tra nsmission oil
to the
inside of t
he
clutch
housing gear and kick
sta rte
r
drive
n
gear.
-
Install
the
frictio
n
plates
and
steel
plates,
starting
with
a
friction
plate a
nd alte
rnat
ing them
Finish
with
a
friction
plate.
CAUTION
If dry
steel
plates
and
friction plates are
installed.
apply transmission
011
to the surfaces of each
plate to avoide
clutch
plate seizure
.
ENGINE RIGHT SIDE 5·"
-
For
KX125
model,
repla
ce the clutcn
hub nut
with
a new one.
-
Tighten the clutch hub
nut to
the specified
torque
.
Tightening Torque
KX1
25:
KX250
:
88 N-m (9 kg -m
,
65 ft
-Ib)
98 N-m
(10
kg-m
,
72
ft -Ib)
-
For
t he
KX250
model
;
set
the
pu sh rod bushing
as
the following
procedures.
a
Mea
s
u
re the
he
ight
CD
which the bushing
protrudes
from the
shaft
e
nd.
1.
Bushing
2
2.
Pu sh
Rod
a
lf
the
height
is 1.5
mm or
less than it, investigate
other
cause
than the bu
sh ing.
olf the
height is
more
than
1
.5
mm, press
the
bus
hing
into the t ransmission
shaft by lightly tapping the
bush ing with
a
brass
hammer until
the
height
is
1.5
mm
.
Be
ca
reful not to deform the
bu
sh
ing
end.
CAUTION
If the bushing
is
pressed in
so
f ar that
the
height
reduces less
than
1.5
mm
,
the
inner
c
hamfered
end
of bushing
rides
over
the
stepped portion of
the
drive shaft
and
the inside
diameter
of
bush-
ing reduces.
In
this case
the push rod cannot be
inserted
into the
bushing or
slides
with dragging
.
0After
pressing
into
the
bush
ing.
insert the push
rod
into
the
drive
shaft.
Check if
the p
us
h
rod can
s lide
smoothly.
light dragging
can
be
cured
by sanding the
push rod
su
rface
by sand
paper.
-
Apply molybden
um
disulfide grease to
the clutch
spring
plate
pusher.
-
Tighten the
clutc
h
spring
bolts to
the
specified
torque.
Tightening
torque
KX125
:
9
.3
N-m
(0.95
kg-m
.
82 in-fbi
KX250
:
8.8
N -m (0.9 kg-m
.
78 in-lbJ

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