Clutch Cover Removal
Drain the engine oil (see Cooling System in the Periodic
Right Lower Fairing (see Frame chapter)
Clutch Cable Lower End [A]
Clutch Cover Mounting Bolts [B]
Turn the release lever [A] toward the rear as shown, and
remove the clutch cover [B].
[C] about 90°
Clutch Cover Installation
Apply silicone sealant to the area [A] where the mating
surface of the crankcase touches the clutch cover gasket.
Sealant - Kawasaki Bond (Silicone Sealant): 56019–120
Replace the cover gasket with a new one.
Apply a non-permanent locking agent to the threads of
the two clutch cover bolts [B].
Tighten the cover bolts.
Torque - Clutch Cover Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)
Release Shaft Removal
Do not remove the clutch release lever and shaft
assembly unless it is absolutely necessary. If re-
moved, the oil seal replacement may be required.
Remove the clutch cover (see Clutch Cover Removal).
Pull the lever and shaft assembly straight out of the clutch
Release Shaft Installation
Apply high-temperature grease to the oil seal lips on the
upper ridge of the clutch cover.
Apply oil to the bearing in the hole of the clutch cover.
Insert the release shaft straight into the upper hole of the
When inserting the release shaft, be careful not to
remove the spring of the oil seal.
Apply molybdenum disulfide grease to the pusher-holding
portion on the release shaft.