KAWASAKI KH & S SERIES FORUM

netbikes · Posted: Sat Feb 02, 2008 9:17 am Post subject: S3 clutch

Hi guys, well I am finally back to doing some work on my S3.
I have bought new friction clutch plates, 7 , but find they do not fit completely into the hub, the last one sits half in, half out. Further to that I find there is a gap between the clutch pusher and the internal rod therefore the lever just flops about.

Now before I did this the old clutch worked but it slipped over 6 thou.

Where am I going wrong?. As far as i am aware I am putting it together correctly, that is the the first plate to go against the clutch hub is a friction followed by a spring ring followed by a steel and so on.

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Chris at
http://auction.netbikes.com.au/

The Wolfman · Posted: Sat Feb 02, 2008 4:36 pm Post subject:

Looking at the exploded diagram, it shows order of fitting:-

friction-spring-steel, etc, all the way and should end in friction-spring-faceplate...... as you said 7 frictions, then 7 springs, 6 steel plates.

the faceplate fits in one (of five) position only, marked by a tiny hole on the edge of the basket and a casting marked spring hole on the plate.
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I used to be a Werewolf, but I'm alright Noooowwwwww!!

netbikes · Posted: Sat Feb 02, 2008 4:49 pm Post subject:

thanks wolfman, I worked it out tonight, a po had fitted an extra steel so it had seven. It also took me a while to see the face plate would only fit correctly in one position. It is all back together now and working fine. However looks like I have stripped the thread in the oil pump where the oil tank line banjo fits but I think it has the wrong screw in it. It is too short to take the little gaskets each side. So perhaps if I get the right screw and gaskets I can get it further up the thread and it might take...
_________________
Cheers
Chris at
http://auction.netbikes.com.au/

The Wolfman · Posted: Sat Feb 02, 2008 5:02 pm Post subject:

:thumright: Glad you got the clutch sorted, it had to be something staring you in the face....
Those pumps are made from papier mache, we've probably all stripped one or other thread at some time.
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I used to be a Werewolf, but I'm alright Noooowwwwww!!

netbikes · Posted: Sun Feb 03, 2008 9:36 am Post subject:

well I took my clutch for a spin today, seems to work fine however i could no go far due to the leaking oil line, have ordered the bolt from Kawasaki here, guess it will be another week before I can really test it out.
_________________
Cheers
Chris at
http://auction.netbikes.com.au/

Triplehappy · Joined: 30 Oct 2008 Posts: 23 Location: Seaside, Oregon

netbikes · Posted: Sun Nov 02, 2008 11:33 pm Post subject:

Hi Triplehappy, I have not renewed the springs and the clutch does not slip.
It get ridden at least twice a week but mainly for short trips, I still need to replace or fix the front wheel before i ride longer. it is buckled, and i should replace the rear wheel bearings and swing arm bushes, they are not problematic, just 35 years old :D
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Cheers
Chris at
http://auction.netbikes.com.au/

Triplehappy · Joined: 30 Oct 2008 Posts: 23 Location: Seaside, Oregon

The Wolfman · Posted: Mon Nov 03, 2008 8:46 am Post subject:

Some of the UK guys have fitted 3x Z1 springs to their clutches (I think on larger bikes though), I did notice however..

My worn H2 springs are now S series length... I wonder?

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I used to be a Werewolf, but I'm alright Noooowwwwww!!