Clutch Cover Removal
Engine Oil (Drain, see Engine Oil Change in the Periodic
Clutch Cable Lower End [A]
Clutch Cover Mounting Bolts [B]
Turn the release lever [A] toward the rear as shown in the
figure, and remove the clutch cover [B].
About 90° [C]
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): 92104-0004
Replace the clutch cover gasket with a new one.
Tighten the clutch cover mounting bolts.
Torque - Clutch Cover Mounting Bolts: 11 N·m (1.1 kgf·m,
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 engine oil to the needle bearings in the hole of the
Apply molybdenum disulfide grease to the pusher-holding
portion [A] on the release shaft.
Install the washer [B] and spring [C].
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.
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