Clutch plates, replace with ZX-10

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by rossguzzi, Nov 4, 2012.

  1. rossguzzi

    rossguzzi 990 Adv.

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    I read somewhere that ZX-10 plates are an exact replacement and cheeper. Now I`m in for a new set soon so may well get these. But I didnt read what year ZX-10 works. Perhaps they are all the same? I dont know.

    Anyone used these like to advise?

    Cheers.
    #1
  2. kamanya

    kamanya Andrew to most

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    I did this a while ago.

    So long as it is not the steel plates and you are only looking for the fiber ones then you are halfway there. The first fiber plate is unique to the KTM and you can get away with not changing it if it is barely in spec and not glazed. The rest can be found from a Kawasaki ZZR 600's & 1100 for the 2006 and before.

    The safest way is to pitch up at a Kawa dealer with one of the plates from your clutch pack and a vernier and ask to rummage around.

    That's what I did.
    #2
  3. gefr

    gefr Life is a trip

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  4. cjracer

    cjracer AWD please!!

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    Or you get get the complete KTM kits with steels, springs and fibers. If it time for new fiber, NEW springs will help to keep the New fibers from slipping more than they should.

    Changing just one part of the system can have you chasing issues down the road.

    We have these in stock.

    Cheaper than the KTM, but still OEM qualitly.


    I find the OEMs last longer than aftermarket.


    If you want just fiber and a new "Special" KTM fiber, we have those too.

    Email for info.
    #4
  5. rossguzzi

    rossguzzi 990 Adv.

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    I just finished inspecting and measuring plates and springs. All seem to be within specs. So thats good !
    My problem seems to be creeping with clutch in. I will be getting bigger jet (the one in it has no number) and I see the hard rubber block under the slave is newish looking but the center hole looks skewed. May replace this.

    Thanks for the other info. I have recorded it for future.

    Cheers.
    #5
  6. cjracer

    cjracer AWD please!!

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    What year bike?

    Could be push rod getting shorter over time/fatigue (03-04 w/ 3 piece unit), or Clutch slave on it's way out also.
    #6
  7. rossguzzi

    rossguzzi 990 Adv.

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    It`s an 03. The bike just came back from a mechanic and he said there was a small pin in the clutch rod that was broken. He replaced it. Slave is not leaking. I will bleed next just in case. Where the ball bearing meets the rod there is a tiny mark in the end of the rod. I think this is ok.
    Cheers.

    Just got the jet drilled out to 0.5 and it drags even more now ! Before I could still get neutral sometimes. Now, I dont think so :(
    #7
  8. cjracer

    cjracer AWD please!!

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    The Pin only holds the rod from spinning and could be broken from installing the slave system wrong. That could cause it to hang up if jammed.

    The 03' has the OLD style 3 piece push rod stock, that should have been pull completely out and inspected or upgraded. If it's gotten shorter from compression over use, this could be an issue. You won't have enough travel to compensate for this in the Slave unit.

    Having a small dot on the end of the shaft is normal, but if it's too big, that's not good.

    With a larger oil jet, a little blip of the throttle might be needed to find nuetral. It's a feel thing, but should not be a huge issue.
    #8
  9. rossguzzi

    rossguzzi 990 Adv.

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    I will pull the whole rod out tomorow. I want to get to the bottom of this ! :1drink
    #9
  10. cjracer

    cjracer AWD please!!

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  11. rossguzzi

    rossguzzi 990 Adv.

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    Update,
    I checked and I have the new rod.
    I put the one steel plate that was slightly grooved back to 'first in' position. It hardly creeps now !
    Is the first plate to go in meant to have a slight groove in it where it meets the Belviere spring and washer?

    I have (hopefully) included some pics of the clutch basket. There is some wear marks from the fibre plates. The pics make it look worse than is in real life.
    Can the wear marks be filed out?
    Just curious.

    Cheers.


    PS how do you upload pics?
    #11
  12. Vicks

    Vicks gets stuck in sand

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    2 options

    photobucket.com = free

    smugmug.com = supports advrider
    #12
  13. rossguzzi

    rossguzzi 990 Adv.

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    Rode it to work and home. Creeping is back.

    I can only think the basket needs replacing and/or the rubber block behind the slave.

    Oh well.
    #13
  14. kamanya

    kamanya Andrew to most

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    Have you made certain that the oder of the discs is right?

    One of the discs is thinner than the rest and is not obviously different with a quick glance, it goes in first. It's called the lining disc part number - 600.32.012.000

    Also the spring has to go in one way too.

    You shouldn't have a wear mark in any of the discs if it was installed right.

    [​IMG]
    #14
  15. rossguzzi

    rossguzzi 990 Adv.

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    I am fairly sure all plates and springs are installed correctly. I will double check the spring. Not sure what they mean by 'Spring Washer open side out'
    Will check in the morning.
    Cheers.

    PS, love these forums.
    I am a long timer on AF1 Forum. My Aprilia`s have not needed this amount of fine tuning, but I am determined to succeed !
    #15
  16. kamanya

    kamanya Andrew to most

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    The spring doesn't lie flat, it is bowl shaped. The "open" side of the "bowl" has to be towards the right hand side of the bike, or towards you as you will be looking at it.
    #16
  17. rossguzzi

    rossguzzi 990 Adv.

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    Ah, thanks for that. Will check tomorow. Looked up the workshop manuel but didnt explain it in that much detail.
    Cheers.
    #17
  18. rossguzzi

    rossguzzi 990 Adv.

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    Update,

    Checked the opening of the spring, correct.
    Checked plates etc again, correct.
    Rod all good.
    Bled slave, air and bits of crap came out. Rode and was ok for a bit then back to creeping.
    Bled more with slave off and tilted/tapped, more air out, clean proper fluid now.
    Rode and again ok for a bit the creep.
    Inspected slave and feel that there is a slight leak and sorce of air getting in.

    I am thinking of getting a Obriens slave with alloy mounting block.
    OR a Rekluse with alloy mounting block.

    Either of these should fix it.

    Cheers for the help.
    #18
  19. Salzig

    Salzig Been here awhile

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    Just to be sure I get it right (my english sometimes sucks), it have to look like this, looking the bike from behind:
    ./
    |
    .\
    At 65k km I think it's time to check my clutch for wear, although it's working fine.
    #19
  20. kamanya

    kamanya Andrew to most

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    Yep.

    Nice way of describing it.
    #20