Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

Clutch Cover
CLUTCH 6-7
Clutch Cover Removal
• Remove:
Engine Oil (drain, see Engine Oil Change section in the
Periodic Maintenance chapter)
Clutch Cable Lower End [A]
Clutch Cover Mounting Bolts [B]
Clutch Cable Bracket [C]
• 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.
• Tighten the cover bolts.
Torque - Clutch Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)
Release Shaft Removal
CAUTION
Do not remove the clutch release lever and shaft
assembly unless it is absolutely necessary. If removed,
the oil seal replacement may be required.
Remove the clutch cover (see Clutch Cover Removal).
•
Pull the lever [A] and shaft assembly out of the clutch
cover.
Release Shaft Installation
• Apply high-temperature grease to the oil seal lips on the
upper ridge of the clutch cover.
• Apply oil to the needle bearings in the hole of the clutch
cover.
• 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
clutch cover.
CAUTION
When inserting the release shaft, be careful not to
remove the spring of the oil seal.
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