CLUTCH REBUILD 99 - ? 1500/1600 Nomad 8/2011

[rolfe]

Reworked the Clutch yesterday on "RED" our 99 1500 G1 Nomad. Never doing this before having reviewed 2 service manuals, checking several Internet sites including KawaNow , Texas Vulcan Riders, talking to Kawasaki USA, and of course getting mentally prepared. before starting the work made all the difference.

One draw back was the use of the New Impact Wrench and used my pancake compressor, just did not work (any ideas why). So I used my 3/4" ratchet and 27mm socket to loosen the bolt using a Copper Penny. I used Silver Metal A/C Tape and folded it around the penny with a long length and it made placing in the gear teeth easier. Another note is CAUTION since the bike is in gear it will attempt to move while using a Ratchet vs. Impact Wrench

So what I replaced

1 Gasket

1 Clutch Spring (used the mean streak spring much much heavier)

3 Limiter Springs

1 Set of Friction Plates

Option:

1 1.5mm steel plate

1 2.0mm steel plate

1 2.3mm steel plate


I did purchase these steel plates and 7 additional 2.0mm plates since these are OEM for at least my model . I just did not want down time on waiting for them if they were bad. Who knows maybe I'll be on Auction Hunters, American Pickers, or Pawn Stars in another 20 years when they find them. Ha

My steel Plates original steel plates are 99.9 % perfect so there was no need to replace.

But I did remove one 2.0 plate and replace with the 2.3 plate just to see what will happen.

From start to finish about 6.5 hours including leaving and site clean up and tool storage. I worked alone, hid, and turned the phone off.

My mileage on "RED" was only 17,300 miles and after reading this seems to be the case ( a bad clutch spring )

Since I have the all Famous Plastic Oil Pump Gear I am assuming that damage was done in the past to it when re installing the Clutch Housing to the Shaft and aligning the Plastic Oil Pump Gear Teeth. assuming that many of these models 1500/1600 have the Light Weight OEM Clutch Springs that fail under 20,000 miles. This is why I believe damage was done to the POG.

I checked my POG out and studied it , looked 100 % okay. I am going to put a Piezo Alarm and Switch in Line to the Water and Oil Warning Lights for added protection. I am just not ready to change out the oil pump gear to a metal gear.


Using the Mean Steak Clutch Spring can be used in the 1500 and 1600 models but check to be sure.

I made this information short but with a bit of new information for everyone. Again between all the Information here on this site and other sites, reading material, just talking, and Kawasaki USA. before ordering parts and starting the project made this project go smoothly.

Really have been test riding "RED" the last few days and in 105 degree heat. Every thing looks and the works mechanically correct.

RED Shifts and Handles the best ever. I rode with a group today and what a pleasure it was. 8/13/2011.



I may revise some information later:


1st. 8/23/2011 the handling and shifting is much much smoother. In town mpg has me well over 35.5 mpg now. Also using the 2.3 steel plate is too me at least a split vs. buying 3rd party washers.



Many Many Thanks To Everyone =r=