Part 2: Kawasaki KLX 250S clutch inspection and reassembly!
Here are some (more on that in a bit) of the parts you will need to put your clutch back together, starting with the upper left and going clockwise we have:
Gasket, Clutch 11060-1325
Gasket, Clutch Cover 11061-0923
Plate-Friction (x7) 13088-0042
Washer (x2) 11009-1344
Gasket, Pump Cover 11060-1328
Measure your clutch springs. Standard length is 3.54cm. Service limit is 3.39cm. As you can see, my springs are just below the minimum. And of course, I didn’t order new ones and as luck would have it they are out of stock until next week…
Add these to your parts list: SPRING (x6) 92145-0637
Measure your friction plates (measure at several points on every plate as they do not always wear evenly):
Standard thickness is 2.92-3.08mm, so these are still within the service limit, but I’ll replace them all the same as they are very cheap.
Visually inspect the 6 steel clutch plates for signs of overheating (discoloration), warp and wear:
There are 6 steel plates, 1 is smooth and 5 are not. The smooth plate goes onto the clutch hub FIRST.
To be continued!!