Steps of Replacing a Clutch on a Kawasaki Zx7

The Kawasaki Zx7 motorcycle has what is known as a "wet" clutch, this is basically another way of saying that the clutch is covered in oil. The clutch uses the friction generated by multiple rotating plates to transfer horsepower from the engine to the transmission The plates are alternately layered with a steel plate followed by a friction plate. Steel plates contain teeth teeth on the inside edge whereas friction plates feature wide teeth on the outside edge.

Tools

To perform this task you will need to have an assortment of Allen sockets on hand along with various standard wrenches and sockets. Purchase an oil pan to contain any oil that leaks out of the clutch. You also will need several shop rags, a magnet on a stick, and a slotted screwdriver. Keep a soft folded towel next to you as you work so you can protect the parts you are removing from being scratched or dented.

Accessing the Clutch

Locate the clutch cable that connects the clutch activator on the handlebar with the bottom of the clutch cover, and remove it. Unbolt the metal clutch cover, and put it on the folded towel. Inside the clutch assembly, you will see pressure plate retainer bolts in a circle. These bolts sit inside of metal spring holders. Remove the bolts, and pull the springs off of the spring holders.

Removing the Clutch

Slide the pressure plate out to reveal a friction plate. Use the stick with the magnet attached at the end in combination with a small slotted screwdriver to pry out each plate in the clutch assembly and remove it. When you reach the bottom of the assembly, the final plate you will remove is going to be another friction plate.

Installing the New Clutch

Identify the first friction plate in your clutch replacement parts. Slide the plate down into the rear of the clutch basket and hub. Install a steel plate next, and continue setting alternating plates on top of each other until you install the final friction plate on top. Replace the pressure plate along with the springs and retainer bolts that hold it in place. Take the clutch cover off of the folded towel, and bolt it back on. Attach the clutch cable to the clutch activator on the handlebar and the bottom of the clutch cover. Take your motorcycle for a short test drive to see if your replacement clutch is adjusted properly and to make sure it isn't slipping.

References

• Scott Stoll, Certified Motorcycle Technician -- Kawasaki and Honda; Tampa, Florida