Kawasaki KX65 Motorcycle User Manual

If dry steel plates and friction plates are installed,
apply transmission oil to the surfaces of each plate
to avoid clutch plate seizure.
Install the friction plates and steel plates, starting with a
friction plate and alternating them, finishing with a friction
Install the hub nut and clutch spring bolts.
Torque - Clutch Hub Bo lt: 64 N ·m (6.5 kgf·m, 47 ft·lb)
Clutch Spring Bolt s: 9 .3 N· m ( 0.95 k gf ·m, 82 in·lb)
Apply molybdenum disulfide grease to the clutch spring
plate pusher.
Clutch Spring Plate Pusher
Shim (as required)
Clutch Pusher
Magneto Cover
Engine Right Side Cover
Friction and Steel Plates Wear, Damage Inspection
Visually inspect the friction and steel plates to see if they
show any signs of seizure, or uneven wear.
If any plates show signs of damage, replace the friction
plates and steel plates as a set.
Measure the thickness [A] of the friction plates [B] and
steel plates with vernier calipers.
If they have worn past the service limit, replace them with
new ones.
Friction Plate Thickness
3.1 3.3 mm
Service L i m it :
2.9 mm
Steel Plate Thickness
1.47 1.73 mm
Service Limit:
1.37 mm
Friction and Steel Plate Warp Inspection
Place each friction plate or steel plate on a surface plate,
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C] The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel Plates Warp
Friction Plate Not more than 0.2 mm
Steel Plate
Not more than 0.15 mm
Service Limit:
Friction Plate 0.3 mm
Steel Plate 0.3 mm