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Discussion Starter #1
I got 39k on the odometer, along with half a dozen track days. Everything is stock except the tires, chain, and break pads. And I had to change the stator at 33k...

Riding home in top gear, I grab a handful of throttle, the RPM's go up, but I don't go any faster, then the RPM's go down and it starts to pull and I go faster.

So, I plan to take it to Kawasaki tomorrow.

Anyone know what it will cost or have the cost breakdown for the labor and parts?

Should I also pay them to check the valves? That has never been done either.

Thanks,
Jeremy

oh, and some pics form last trackday
 

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As originally posted by invader:

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:

http://www.ninja650r.co.cc/Clutch Springs How To.pdf

http://homepages.slingshot.co.nz/~shanetp/How to_files/How to Replace Clutch Springs on a Kawasaki Ninja650R.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/the-70532/06-dsh-07-2006-2007-Kawasaki/Detail

http://www.phatperformanceparts.com/SearchResults.asp?Search=501-50-05055&Search.x=16&Search.y=11

Complete clutch kits:

http://www.starcycle-usa.com/servlet/the-41978/06-dsh-07-2006-2007-20008/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.)

http://www.barnettclutches.com/products/clutch_plates_springs.aspx?type=clutches_other&clutch_make=Kawasaki&clutch_cc=650

http://www.kawasakiversys.com/forums/showthread.php?t=5314
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.)

http://www.kawasakiversys.com/forums/showthread.php?t=8900

http://www.kawasakiversys.com/forums/showthread.php?t=5805
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) http://www.phatperformanceparts.com/SearchResults.asp?searchWText=&sortBy=&page=&Extensive_Search=&Config_SearchResultsRows=&RefineBy_Manufacturer=&search=csk7&mfg=

(1st selection) http://www.phatperformanceparts.com/SearchResults.asp?Search=501-50-05055&Search.x=16&Search.y=11

How to replace clutch springs:

http://www.riderforums.com/ninja-650r-performance-upgrades/29275-how-replace-clutch-springs.html

http://homepages.slingshot.co.nz/~shanetp/How to_files/How to Replace Clutch Springs on a Kawasaki Ninja650R.pdf

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

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do it yourself clutch repair.

I think it cost me $70 for Versah springs and plates. Make sure you use the gasket sealant that is specific to oil areas. Does not take long, maybe an hour and a half.

:D
 

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Discussion Starter #5
well, I need it for a track day on the Dec 1st. So, I wnat ahead and took it to Kawasaki.

Turns out, the cable was sticking.

New clutch cable $200 something.

Why didn't I think of that...
 

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Discussion Starter #7
Yes...and I know. Parts plus labor and they charge $75/hour for labor and I think it is a minimum of one hour.

This is why I ususally use non stealership shops (P1 raching, Woopies Cycles, Motorcycles Unlimited)

But I was in a bind...
 

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well, I need it for a track day on the Dec 1st. So, I wnat ahead and took it to Kawasaki.

Turns out, the cable was sticking.

New clutch cable $200 something.

Why didn't I think of that...

 
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