zxr250c clutch replacement

[bonus]

Just wondering how much of a mission is it to replace the clutch as mines now slipping at 12-13 rpms, im fairly mechanically minded but have never replaced a clutch before, i have a workshop manual too :)

Cheers
Leon

[xwhatsit]

Bit of a pain in the arse, as you have to pull off the side cover and fuck about with big scary nuts and springs and shit.

Are you sure it's the clutch's fault? Have you ruled out other issues for clutch slip, such as oil? Change your oil, make sure you put in proper motorcycle oil, not car stuff as that will cause clutch slip. Check adjustment on the lever, too -- could be that it's worn, so it's not engaging properly and all you need to do is adjust the cable/lever so it bites properly.

Changing the whole clutch seems pretty drastic. You don't often hear about these being replaced, especially on a relatively recent 250cc bike.

Try posting this or having a mod move it into the Mechanical section of the forum.

[rookie]

Changing the whole clutch seems pretty drastic. You don't often hear about these being replaced, especially on a relatively recent 250cc bike.



If you know that you're using the right oil and you know that things cant be improved by adjusting the lever...than you're right - further action is required.

All's you need is a "clutch kit" from a bike store (approx $105-also add $70 for oil and filter), and dont worry they are a common item that needs doing. I had mine done at approx 47,000km - I was also getting alot of slip. Another ZXR owner is also going through the same thing with similar km's on the clock.

I didnt have the time to do it myself so i chucked it into a bike shop (adds 1 hour labour). But you have the manual so i think you should be able to manage. All it involves is replacing the fibre plates, the spring and a couple of gaskets.

[Brett]

If you know that you're using the right oil and you know that things cant be improved by adjusting the lever...than you're right - further action is required.

All's you need is a "clutch kit" from a bike store (approx $105-also add $70 for oil and filter), and dont worry they are a common item that needs doing. I had mine done at approx 47,000km - I was also getting alot of slip. Another ZXR owner is also going through the same thing with similar km's on the clock.

I didnt have the time to do it myself so i chucked it into a bike shop (adds 1 hour labour). But you have the manual so i think you should be able to manage. All it involves is replacing the fibre plates, the spring and a couple of gaskets.

What he said.

You dont need to do the whole clutch, only the friction plates any maybe the springs if they are naffed.
Should only take you an hour and a half or so to do, and manual explains relatively well how to do it.

[xwhatsit]

Would still check out if making sure it's got proper oil in it and the clutch adjustment is set correctly before replacing the clutch.

Is this a common thing on ZXRs?

[Brett]

I dont think it is too common, no more than any other bike. On one of my ZXR's, I put a new clutch in at 20,000kms and rode the bike relatively hard for over 20,000kms (wheelies, fast shifts flat shifts etc.) and it was still working perfectly when I sold it. That said, I rode it hard but looked after it well...

[bonus]

Yeah it has fresh oil in it aye and the correct stuff, ill try adjusting the gear shifter and see if that helps,cheers guys :)

[rookie]

ill try adjusting the gear shifter and see if that helps,cheers guys :)

Um...yeah the clutch lever...left hand lever on the bars. Check the adjustment at the bottom of the cable too...near the idle adjuster above the clutch housing

[rookie]

Is this a common thing on ZXRs?

They're a common thing on any thrashed un-maintained bike.

[bonus]

opps yeah i ment the clutch lever, seems ok, but yeah the gears engage nice and firmly but just hitting a particular rev point and it slips, so ill look into getting a clutch kit

[bonus]

can anyone tell me how many steel and fibre plates there are in total???

[rookie]

can anyone tell me how many steel and fibre plates there are in total???

I chucked mine into a shop. The manual doesnt define the number of plates.
Just get a zxr clutch kit...i wouldnt expect that you would need to define the number of replacement plates.

[bonus]

yeah thats what i thought, i emailed my local kawasaki dealer asking the cost of a clutch kit installed and all i got back was the cost of each individual steel and fibre plates

[mikey62]

Raster came over to my place on Sunday night and we did a change over on the ZZR. If your mechanically minded and have the manual then its a piece of piss. Just matter of re-setting the springs etc. Cheers to Raster for the help.

[Buddy L]

Just remember that the spacers wear out the same as the fiber plates, their should be about 7 or more plates, ( just from looking at other bikes), bike shop would be the best bet to get it sorted, if you haven't done anything like this before, but easy if you have the right parts (tools).
10 easy steps*

1) Drain oil
2) Take off clutch cover (will need new gasket to replace old one)
3) Remove clutch springs and main clutch basket cover. (clean in petrol or cleaning product)
4) Remove fiber plates and spacers. ( remember which order they go in)
5) Leave clutch basket in, if looks worn eg. heaps of slop between the fiber plates and the basket then get the shop to remove it (may need specialised tools to take it off.) and replace basket
6) Replace the fiber plates and spacers in correct order
7) Replace the basket cover and replace old springs or get new ones and do up to the correct toque settings.
8) Replace engine cover with new gasket.
9) And new oil, the correct oil for the bike.
10) if worst comes to worst go to the bike shop and don't quote me on it.:dodge: :done:

[raster]

Did it on a ZZR 400 (had only done 30,000Ks) which is very similar, took about 1 hour, hardest part was getting the plates out as the oil sticks them in, bent bit of wire fixed that.
Keep things clean. If you need to remove the clutch cage use a rattle gun as I broke one of mine, I even made up a massive great holding tool like the manual told me to, which didn't work, rattle gun with correct size socket took 30 seconds.