Clutch
The wet multi-plate clutch: lever free-play adjustment, friction/steel-plate and spring wear limits, the fastener-torque table, and clutch removal/installation plus the full inspection set.
Chapters· Clutch
Source: Service Manual — pp. 6-1 … 6-20src: Kawasaki VN2000-A1 Service Manual — Periodic Maintenance (Torque & Locking Agent / Specifications tables, pp. 2-7…2-13)
Clutch
| Item | Standard | Service limit |
|---|---|---|
| Clutch lever free play | 2 – 3 mm | — |
| Friction-plate thickness | 3.3 – 3.5 mm | 3.1 mm |
| Friction / steel-plate warp | ≤ 0.2 mm | 0.3 mm |
| Clutch-plate assembly length | 51.32 – 52.32 mm | — |
| Clutch-spring free length | 81.17 mm | 77.5 mm |
| Primary-chain 20-link length | 190.50 – 190.97 mm | 193.4 mm |
The SM’s inspection page prints the clutch-spring free length as “81.7 mm (3.196 in.)”, but 3.196 in = 81.17 mm and the Specifications table gives 81.17 mm — so 81.17 mm is the correct metric figure (the 81.7 is a manual typo). Both sources agree the service limit is 77.5 mm.src: Kawasaki VN2000-A1 Service Manual — Periodic Maintenance (Torque & Locking Agent / Specifications tables, pp. 2-7…2-13)
Clutch fastener torques. Remarks: EO engine oil · MO molybdenum-disulfide oil · L locking agent · S tighten in sequence · R replace.
Clutch fasteners
| Fastener | Torque | Remarks |
|---|---|---|
| Clutch-hub nut | 135 N·m | R, MO |
| Cam-damper bolt | 69 N·m | — |
| Outer clutch-cover bolts | 12 N·m | S |
| Inner clutch-cover bolts | 12 N·m | S |
| Clutch-spring bolts | 9.8 N·m | — |
| Outside-plate bolts | 9.8 N·m | L |
| Inside-pipe / primary-chain-guide bolts | 9.8 N·m | — |
| Clutch-release-lever bolt | 5.9 N·m | — |
| Clutch-cover oil-drain plug | 21 N·m | — |
| Plug on outer clutch cover | 20 N·m | — |
Replace the clutch-hub nut with a new one and apply molybdenum-disulfide oil to its threads and flange before torquing to 135 N·m, holding the hub with clutch holder 57001-1243.
Free-play set to 2–3 mm; cable removal, lubrication and lever fitment.
Lever free play (2–3 mm) is set on the Periodic Maintenance schedule using the cable adjusters: take up the bulk of the adjustment at the mid-cable adjuster (locknut and adjusting nut), then fine-tune at the lever adjuster. To remove the cable, give it plenty of play first, line up the slots in the lever, locknut and adjuster, free the inner-cable tip from the release lever, and tape the release lever forward against the outer cover so the release shaft cannot fall out. Lubricate the cable per General Lubrication. Fit the lever so the punch mark on the handlebar aligns with the clamp mating surface.src: Kawasaki VN2000-A1 Service Manual — Periodic Maintenance (Torque & Locking Agent / Specifications tables, pp. 2-7…2-13)
- Periodic Maintenance: clutch →Free-play inspection & adjustment intervals.
- Owner's manual: shifting & clutch →How free play affects engagement and shifting.
Outer-cover off, plates and hub out; reassembly with the 135 N·m hub nut and oiled plates.
Removal
The engine stays in the frame; drain the oil first.
- 1
Drain the engine oil (see Periodic Maintenance) and remove the left footboard (Frame chapter).
- 2
Disconnect the clutch cable, remove the release-lever bolt and lever, then the outer-clutch-cover bolts and cover.
- 3
Remove the outside plate (with its bolts) and oil pipe, then the clutch-spring bolts and spring plate with springs.
- 4
Take out the washer, thrust bearing and push rod, then lift out the friction and steel plates.
- 5
Hold the clutch hub with the clutch holder and remove the clutch-hub nut; take off the washer, spring washer and clutch hub.
Special tool: clutch holder 57001-1243.
Installation (key steps)
Reverse of removal; the torque and lubrication call-outs below are the critical ones.
- 1
Apply molybdenum-disulfide oil to the cam-damper X-marks, fit it to the crankshaft with the spring holder, springs and retainer, then torque the cam-damper bolt (clutch holder).
Torque69 N·m - 2
Fit the spacer, clutch hub, washer and spring washer (its “OUT SIDE” mark facing out). Fit a NEW clutch-hub nut, apply molybdenum-disulfide oil to the threads and flange, and torque it with the clutch holder.
Torque135 N·m - 3
Install the friction and steel plates, starting with a friction plate and alternating.
CautionIf new, dry plates are fitted, oil every plate surface with engine oil first to avoid clutch seizure.
- 4
Refit the push rod, thrust bearing, washer and spring plate, then torque the clutch-spring bolts.
Torque9.8 N·m - 5
Apply liquid gasket (Kawasaki Bond 92104-1064) to the inner-cover mating surface and fit the cover within 20 minutes; torque the inner- then outer-cover bolts in their sequence.
Torquecovers 12 N·m
Friction/steel-plate thickness & warp, spring free length, primary-chain wear and the housing/hub checks.
Inspect friction and steel plates for seizure, discoloration (overheating) or uneven wear and replace any damaged plate. Measure friction-plate thickness at several points (standard 3.3–3.5 mm, service limit 3.1 mm). Check warp by measuring the gap to a surface plate with a feeler gauge (≤ 0.2 mm standard, 0.3 mm limit) — replace a steel plate with one of the same thickness. If the assembled clutch-plate length is out of the 51.32–52.32 mm range, adjust it by swapping in a thicker or thinner steel plate (1.6 mm part 13089-1080 or 2.3 mm part 13089-1081).src: Kawasaki VN2000-A1 Service Manual — Periodic Maintenance (Torque & Locking Agent / Specifications tables, pp. 2-7…2-13)
Measure each clutch spring’s free length and replace any shorter than the 77.5 mm service limit (standard 81.17 mm). Check the primary chain by holding it taut and measuring a 20-link length (standard 190.50–190.97 mm, limit 193.4 mm) at several places; if it exceeds the limit, replace the chain together with its sprockets and the crankshaft. Inspect the clutch-housing fingers and the outer-hub splines where the plate tangs and teeth ride — replace the housing or hub if grooved or notched, and replace the affected plates too.src: Kawasaki VN2000-A1 Service Manual — Periodic Maintenance (Torque & Locking Agent / Specifications tables, pp. 2-7…2-13)
- Periodic Maintenance: clutch & oil →Free-play and engine-oil-change intervals.
- General specs: drive train →Primary 1.500 (48/32), wet multi-disc clutch.
- Maintenance schedule →Clutch-operation inspection intervals.