Clutch Replacement Parts - Kawasaki Versys Forum
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post #1 of 3 (permalink) Old 03-06-2016, 06:14 AM Thread Starter
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Clutch Replacement Parts

Has anyone replaced a clutch in the Versys? It doesn't look to be that hard, but I was wonder what parts should be replaced so that I can order them all at once. I really don't want to crack it open and find out that I need more parts.

Steve

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post #2 of 3 (permalink) Old 03-06-2016, 09:54 PM
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You may only need to upgrade your clutch springs... You could also replace your clutch discs if they are worn. A new clutch cover gasket would be good too.

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Originally Posted by invader View Post
Some have replaced the clutch springs for stiffer ones, but I'm not sure if anyone has also replaced the clutch plates.

How to replace clutch springs:

ninja650r - Instagram

http://homepages.slingshot.co.nz/~sh...0Ninja650R.pdf

It is possible to remove clutch cover without draining oil, by leaning it over more than side stand allows...

Barnett's clutch springs are about 20% stiffer than stock, whereas EBC clutch springs are about 10-15% stiffer. EBC's CSK7 clutch spring set (5) is available for only $10.29. Barnett 501-50-05055 (MT-55-5) spring set for $15.95.

http://www.starcycle-usa.com/servlet...awasaki/Detail

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Complete clutch kits:

http://www.starcycle-usa.com/servlet...7-20008/Detail ($152.95)
EBC's SRK kits have a more aggressive/faster clutch takeup. "For use in heavy sport bikes and production based race bikes." Includes high strength springs, Kevlar lined fiber plates, and steel separator plates to allow the clutch to be rebuilt to exact original stack height.

Barnett clutch kit for $161.95: http://www.starcycle-usa.com/servlet/Detail?no=43193

Same part numbers for Versys, Ninja 650R and ER-6 on complete or partial clutch kits. (Only the 2009 Ninja 650R for which a complete kit is not available, uses six # 401-45-089002 tempered steel metal plates instead of five # 401-45-089002 and one # 401-45-103002.)

Barnett Tool & Engineering

Ninja 650 clutch - Kawasaki Versys Forum
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Originally Posted by invader View Post
It is common to replace only the weak/weakened clutch springs for stiffer aftermarket ones for sufficient clamping force, hence the links instructing how to do so... Inexpensive and effective upgrade, without the need for new clutch plates. You can always measure your plates to confirm, but they should still be fine, especially if they just started slipping when engaged and under load.

Clutch Specifications-

Friction Plate Thickness:
Standard: 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.)
Service Limit: 2.8 mm (0.110 in.)

Friction Plate Warp: 0.15 mm (0.16 in.) or less 0.3 mm (0.012 in.)

Steel Plate Warp: 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.)

Clutch Spring Free Length: 33.6 mm (1.32 in.) 32.6 mm (1.28 in.)

Clutch Wear and Replacement - Kawasaki Versys Forum

Clutch Slippage - Kawasaki Versys Forum
Quote:
Originally Posted by invader View Post
Yeah, I don't seem to need them yet, but some have simply upgraded the clutch springs with stiffer ones.

Barnett and EBC clutch springs are about 10% stiffer than stock.

EBC's CSK7 clutch spring set (5) is available for only $8.95. Barnett 501-50-05055 (MT-55-5) spring set for $15.95.

(1st selection) Motorcycle Parts, Motorcycle Accessories – PhatPerfomanceParts.com

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How to replace clutch springs:

How to: replace clutch springs

http://homepages.slingshot.co.nz/~sh...0Ninja650R.pdf

It is possible to remove clutch cover without draining oil, by leaning it over more than side stand allows.
How to: replace clutch springs
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post #3 of 3 (permalink) Old 03-12-2016, 10:55 AM Thread Starter
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I haven't pulled it apart yet and I'm not sure I need to do anything with it. It only seems to slip a little when I am riding hard and shifting in the higher gears. It is probably more how I'm shifting. Thanks for the detailed info!

Steve

I bought a motorcycle because my wife said that I couldn't! Now I have two and she still says I can't have another one!
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