Can anyone help me out with my clutch?

Discussion in 'The Garage' started by bamaroll29, Feb 20, 2013.

  1. bamaroll29

    bamaroll29 n00b

    Joined:
    Feb 17, 2013
    Oddometer:
    6
    I have a 1998 Ke100 that I'm working on. I have the service manual but it says nothing specific to my question...

    I've removed the clutch to unstick the plates. I have it fixed and need to install it back onto the idling shaft. When the shaft sticks out of the crankcase, there is a washer, then a big spring that goes into the back of the clutch hub, then the plates go on, then the clutch plate with mini springs, and then to hold it all on there is another washer and a CIRCLIP. My question is, is the circlip supposed to be flush with the clutch pushed back exposing a little of the end of the idle shaft, or is the circlip supposed to be at the very end of the the shaft allowing the clutch assembly to move a little bit? It's not a huge gap, but I feel like the circlip needs to be in the right place. Also, there is an arrow on my clutch plate that is not mentioned in my manual. Does anyone know what this could be?
    Thanks for any advice!
    #1
  2. CycleDoc59

    CycleDoc59 Wrench Rider

    Joined:
    May 24, 2006
    Oddometer:
    984
    Location:
    East Virginia
    I'm not familiar with that particular bike, but circlips usually fit into
    a particular notch. Also, if it helps, clutches stick together if
    they are dry, or sit without use for long periods. The bonded plates
    should be cleaned, then soaked with clean oil before installation.....
    It may help to pull up a schematic of the clutch on Bike Bandit or similar site as below:
    http://www.bikebandit.com/houseofmotorcycles/1998-kawasaki-ke100-ke100b/o/m149725#sch429768
    #2
  3. bamaroll29

    bamaroll29 n00b

    Joined:
    Feb 17, 2013
    Oddometer:
    6

    Perfect answer, I just checked the shaft and it has a little notch for it to go. I overlook the smallest things! Theres also another notch further down the shaft...still don't know what that one's for though. I read that the arrow on the spring plate is is supposed to line up with a dot or something on the clutch hub. Correct me if I'm wrong though. I will be soaking the clutch plates before putting them back together as well.
    #3