45014 (DRZ-LTZ CLUTCH KIT).cdr
Contents
1. YOSHIMURA RESEARCH amp DEVELOPMENT OF AMERICA INC SUZUKI 2000 03 DR Z400 KAWASAKI 2003 KFX400 SUZUKI 2000 03 LT Z400 KAWASAKI 2003 KLX400 PERFORMANCE CLUTCH KIT PART No 45014 O Be sure to carefully read the instruction manual before starting installation O While working keep these instructions at hand and proceed with the work in accordance with the instructions O These instructions should be retained until the product is scrapped PART LIST DESCRIPTION High Performance Clutch Friction Plate v z NO Le Yoshimura Clutch Springs _ _ 6 _ 6mm Heaw Duty Clutch Spring Bolts 6 Applicable models SUZUKI DR Z400Y EY 2000 2003 KAWASAKI KFX400 2003 SUZUKI LT Z400 2003 KAWASAKI KLX400 2003 Do not use this product for other models than listed above Please read this manual and follow the instructions carefully To emphasize special WARNING information the symbol 44 and the words WARNING CAUTION and NOTE have special Indicates potential hazard that could result in meanings Pay special attention to the LAAU messages highlighted by these signal words CAUTION CAUTION NOTE NOTE Indicates special information to make Indicates potential hazard that could result in maintenance easier or instructions clearer vehicle damage Installation Procedures Page 2 Preparation prior to installation Read instructions carefully Lay out all2. ng bolts Note do not use stock spring retainers under supplied spring bolts see diagram on page 3 Fig 5 9 Tighten the clutch spring set bolts securely in diagonal stages Fig 5 Torque bolts to 1 0 kg m 7 0 lb ft 10 Install clutch cover Check carefully to ensure o ring gasket is correctly seated Bolt with plastic washer is used on cover bolt at location indicated by arrow on Fig 4 CLUTCH ADJUSTMENT Clutch lever free play should be adjusted after installation of the Yoshimura Clutch Kit Adjust clutch lever play to 10 15 mm 0 4 0 6 in Clutch free play should be readjusted after 6 8 hours of use CHECK ENGINE OIL LEVEL Check Engine oil level after engine has been warmed up add as necessary
3. olts see diagram on page 3 8 Tighten the clutch spring set bolts securely in diagonal stages Fig 3 Torque bolts to 1 0 kg m 7 0 lb ft 9 Insert dowels in engine case Fig 2 Install clutch cover using new gasket not supplied Suzuki Part 11482 07G00 CLUTCH ADJUSTMENT Clutch lever free play should be adjusted after installation of the Yoshimura Clutch Kit Adjust clutch lever play to 10 15 mm 0 4 0 6 in Clutch free play should be readjusted after 6 8 hours of use CHECK ENGINE OIL LEVEL Check Engine oil level after engine has been warmed up add as necessary Installation Procedures DR Z400 amp KFX400 INSTALLATION 1 Using a suitable container soak the new clutch friction plates in fresh engine oil for 15 20 minutes 2 Remove clutch cover Fig 4 3 Loosen the clutch spring set bolts working In diagonal stages Fig 5B 4 Remove the clutch pressure plate clutch drive plates and clutch driven plates Note On the furthest inside clutch plate there are 2 large diameter spring washers which must be removed from the hub Fig 6 These are not used in the Yoshimura clutch kit 5 Install new friction plates onto hub starting with a friction plate and alternating steel clutch plates in between each Note Steel clutch plates should be inspected for servicibility in accordance with Suzuki Service Manual 8 Install clutch pressure plate using supplied clutch springs and spri
4. onds or sealants When tightening cylinder head and crankcase nuts and bolts tighten the larger sizes first Always tighten the nuts and bolts from the inside working out diagonally and to the specified torque Whenever you remove oil seals gaskets packing O rings self locking nuts locking washers cotter pins circlips and other specified parts be sure to replace them with new ones Also before installing these new parts be sure to remove any left over material from the mating surfaces Never reuse a circlip When installing a new circlip take care not to expand the end gap larger than required to slip the circlip over the shaft After installing the circlip always ensure it is completely seated in its groove and securely fitted Use a torque wrench to tighten fasteners to the specified torque Wipe off grease and oil if a thread is smeared with them After reassembling check parts for tightness and proper operation Installation Procedures Page 3 Clutch removal and installation should be done in accordance with the Suzuki Genuine Service Manual ALOE During installation and reassembly it is critical to check all clearance values specified in the Suzuki Service Manual Failure to do so may result in severe engine damage If there are any problems encountered during installation and reassembly please contact Yoshimura R amp D technical support at 909 628 4722 CAUTION After disassembling removed
5. parts and tools in a clean area Visually inspect parts for possible damage from shipping AWARNING Engine and exhaust system can be extremely hot Let Motorcycle cool down before beginning installation GENERAL PRECAUTIONS A WARNING Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the Motorcycle When two or more persons work together pay attention to the safety of each other When it is necessary to run the engine indoors make sure the exhaust gas is forced outdoors When working with toxic or flammable materials make sure the area you work in is well ventilated and that you follow all of the manufacturer s instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil radiator and exhaust system until they have cooled After servicing the fuel oil engine coolant or exhaust systems check all of the lines and fittings relating to the system for leaks If parts replacement is necessary replace the parts with SUZUKI Genuine Parts or their equivalent When removing parts that are to be reused keep them arranged in an orderly manner so that they may reinstalled in the proper order Be sure to use special tools when instructed Make sure that all parts used in reassembly are clean Lubricate them when specified Use the specified lubricants b
6. parts should be well cleaned and dried Inspect all parts to ensure they meet the service limits as defined in the Suzuki service manual Clutch Assembly Diagram kaa Bi 1 Bolt 2 Spring retainer 3 Spring 4 Pressure plate 5 Clutch release camshaft 6 Bearing 7 Push Piece 8 Clutch sleeve hub nut Yoshimura Version 9 Washer 10 Clutch sleeve hub 11 Washer 12 Primary driven gear assembly 13 Spacer 14 Pushrod 15 Driven Plate 16 Drive Plate Friction Plate Installation Procedures LT Z400 amp KLX400 INSTALLATION 1 Using a suitable container soak the new clutch friction plates in fresh engine oil for 15 20 minutes 2 Remove clutch cover Fig 1 3 Remove gasket and dowel pins Fig 2 4 Loosen the clutch spring set bolts working In diagonal stages Fig 3 5 Remove the clutch pressure plate clutch drive plates and clutch driven plates Note On the furthest inside clutch plate there are 2 large diameter spring washers which must be removed from the hub Fig 6 These are not used in the Yoshimura clutch kit 6 Install new friction plates onto hub starting with a friction plate and alternating steel clutch plates in between each Note Steel clutch plates should be inspected for servicibility in accordance with Suzuki Service Manual 7 Install clutch pressure plate using supplied clutch springs and spring bolts Note do not use stock spring retainers under supplied spring b
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