Thursday, August 4, 2011
Re-Installing motorcycle clutch plates on 83' kawasaki zx1100. Need to know the order of the plates/spacers.?
They go friction -steel -friction -steel- friction-steel and so on until all the plates are put in.Springs get tightened all the way with about 14 ft lbs of torque,not much just a little past snug.The first friction plate in, rests against the inside pressure plate and the last plate in rest against the outside pressure plate.When assembled correctly the clutch is constantly engaged until you use the release mechanism(clutch lever) to relieve it of the spring pressure.If you want to see an entire schematic of your clutch-go to bikebandit.com-under oem stuff look up your bike and you can see how the whole pak is assembled. Need help ? just holler.....@@EDIT-one more time-remove the cable from the lever and the case cover attachment.Does it move freely within the casing,if it doesn't lube it till it does.If you remove the case cover and just look at the inside of it you will understand how it works.When you pull the clutch lever it moves the actuator on the inside towards the opposite side of the motor.Look in the center of the actuator where the hole is,that is where the dis-engagement rod goes that pushes the clutch open to disengage when you pull the clutch lever.That rod must be in the hole when you put it together.There should be a small spring on the inside of the case cover that returns the actuator to a start position automatically.If you have the case cover on correctly with the dis engagement rod in the actuator hole--then put the cable ends back on each lever and actuator and then adjust the lever screw on top till there is that 1'8 inch of play.Now go back to the case cover and break the locknut loose on the slotted screw.Turn the slotted screw in,if it has some resistance when you turn,it is set to tight.Turn it c.c. until you feel no pressure and it turns easily.Now turn it back in until till you feel the slightest pressure and then back it of 3/4 of a turn and re lock the jam nut...FYI.when you turn the slotted screw in, what you are really doing is moving the whole inner assembly that holds the dis engagement rod towards the opposite side.When you pull the clutch lever the inside unit twists in a rotation towards the oppsite side,pushing the rod and dis engaging the clutch.If you do it like I said you should be riding tomorrow.If not e me and I will try to help you out.
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