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Help How many plates in the clutch stack?

Discussion in 'Kawasaki 250cc In-line 4's' started by DamnitLaverty, Mar 18, 2017.

  1. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    Hey all, trying to answer this BEFORE I tear this bike down again instead of after.

    Clutch is slipping, and KLR 650 discs look to be a direct swap. I'm just not sure how many I need! Anyone know how many plates and discs I need?

    Thanks!
    -M
     
    DamnitLaverty, Mar 18, 2017
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  2. kiffsta

    kiffsta Senior Member

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    • Like Like x 2
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    kiffsta, Mar 18, 2017
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  3. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    Is that 5 + 5 steel or 5+4?

    Thanks for the lead!
     
    DamnitLaverty, Mar 18, 2017
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  4. kiffsta

    kiffsta Senior Member

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    I cant recall, maybe replace the fibres only and clean your steel plates up and reuse them, there are 2 different part numbers for the zxr clutch steel plates, I think they went

    fibre - plate 1 , plate 2, fibre - plate 1 , plate 2, fibre - plate 1 , plate 2,fibre - plate 1 , plate 2, fibre

    Which makes 5 x fibres
    4 x plate 1
    4 x plate 2

    Its been so long since I did a clutch on one of these

    This guy is selling a kit of 8 plates which supports my theory above

    http://www.ebay.com.au/itm/ZXR250-K...339702?hash=item2ef82f37f6:g:oBcAAOSwHMJYPNp2
     
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    kiffsta, Mar 18, 2017
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  5. kiffsta

    kiffsta Senior Member

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    I was right

    plates.PNG
     
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    kiffsta, Mar 18, 2017
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  6. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Here's a handy youtube vid on the ZXR250 clutch

     
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    Linkin, Mar 18, 2017
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  7. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    IMG_6422.JPG I had the manual, but I didn't think to count discs in the drawing, and the manual didn't say.

    I'm watching the video now- just came in from the garage where I was doing the same damned job on the Ducati. After 50k miles it was starting to slip too. It just alternates steel and fiber, but there's like 16 of the dang things.
     
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    DamnitLaverty, Mar 18, 2017
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  8. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    Hmm guess I'm gonna build a fancy stack like he did. Time to put the list together and start saving my pennies!
     
    DamnitLaverty, Mar 18, 2017
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  9. sharky

    sharky Well-Known Member

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    20170318_202159.jpg I think there a standard part, I have heard that the gpx 250 clutch and basket is the same as a zxr also
     
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    sharky, Mar 18, 2017
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  10. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    So yeah. Ordered the parts today. They come on a combination of 636 and KX125 here in the states what a combo. Cost me about a THIRD of the clutch I just did in the duc, too. Should have it by Thursday.
     
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    DamnitLaverty, Mar 19, 2017
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  11. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    Ok so dumb question. How many of you bother with the clutch cover gasket? Can I cheat and just use Kawi-bond in its place? The manual says Kawi-bond AND a gasket... and I don't wanna spend 32 bucks for the gasket. (It's the shipping that screws me). Ima go get some gasket paper today, it's better than nothing I guess, but I hate how those always come out. I'd almost rather skip it and bond the bastard in place like the Ducati. :)
     
    DamnitLaverty, Apr 3, 2017
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  12. sharky

    sharky Well-Known Member

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    I use Loctite blue gasket maker for all the side covers, dabbed on lightly with a finger,never had a leak. I prefer paper gasket for the water pump and sump gaskets, but the blue loctite works on them aswell.
     
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    sharky, Apr 3, 2017
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  13. DamnitLaverty

    DamnitLaverty Doing things the hard way since '78!

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    I'm aiming for brushed on but we're in the same ballpark. Thanks!
     
    DamnitLaverty, Apr 3, 2017
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  14. kiffsta

    kiffsta Senior Member

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    A paper gasket with gasket goop should be fine, as long as the surfaces are clean, just remember it is a wet clutch !!!
     
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    kiffsta, Apr 3, 2017
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