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Help ZZR250 clutch strip down

Discussion in 'Kawasaki 250cc Twins' started by Phteven, Jul 2, 2017.

  1. Phteven

    Phteven Member

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    hi guys.
    i have been having issues with my clutch and have now pulled my clutch apart and possibly figured it out. now just need some confirmation from some of the pros out there.

    i have a 2006 zzr250 and the only service manual i could find is for the ninja 250r with a supplement for older models and i am having trouble making sure i am going off the correct specs.

    i have found the clutch spring free length for the ninja should be
    standard: 39.4mm (1.55in.)
    service limit: 37.6mm (1.48in.)

    the ones i have pull out of my clutch are 31ish mm (i dont have fancy digital veniers)

    since there is so much difference i figure it is severely flogged out or supposed to be different between the earlier and later models.

    TIA
    Steve.
     
    • Agree Agree x 1
  2. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Is the clutch slipping all the time or most of the time ?

    The service manual say they should be 32.8mm long, and 31.7mm is the service minimum
    You might be able to use a 1mm - 1.5mm thick washer under the spring's as a temporary fix ?
     
  3. Phteven

    Phteven Member

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    Some of the time. Mostly during gear changes. Also suffers bad clutch drag

    Sent from my SM-G950F using Tapatalk
     
  4. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    The service manual is apparently the same as the earlier EX250F 1997-2007

    Clutch slipping is worn out spring's, worn out plate's or adjustment,
    drag is normally an adjustment thing, clutch cable may be stretched too?
     
  5. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  6. Phteven

    Phteven Member

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    Going off the manual the friction plates have to be between 2.92mm and 3.08mm and these are reading 3mm as is but again cant measure excact

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  7. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    When you adjusted the freeplay at the lever to give you 3mm movement, did you back it off and take up most of the slack at the bottom of the cable first?
     
  8. Phteven

    Phteven Member

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    Yes i did.

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  9. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    What oil is in it?
     
  10. Phteven

    Phteven Member

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    Dunno what was in it when i got it but wasnt doing all that good so did filter change and filled with motul and since this thing chews through the oil like no tomorrow have been topping up with a cheaper castrol and probably all castrol by now. Now that oil is drained will be filling with castrol again.

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  11. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Motul is no good in my experience. Check the oil you are putting in for anything about 'friction modified' or 'energy saving' - this indicates the oil has additives that will ruin a wet clutch, requiring replacement of the friction plates.

    At work we use shell advance ax-7, which is jaso ma2 approved for use in motorcycles with wet clutches
     
  12. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I use Castrol 15W50 in all my bike's, never had a problem with it, $30.59 for 4 litre's at Supercheap atm
    Say's it surpasses JASO MA, MA2, API SG specifications.
    My oil is still golden after 5000 km's, but it's getting changed this week anyway

    It might be worth spraying some Threebond Super Engine Conditioner down each spark plug hole and letting it sit for a while, then start it up and give it a run up to operating temp's.
    Then do it again a couple of times to clear out any carbon and burnt oil sitting in the ring's and ring groove's of your piston's
     
    Last edited: Jul 2, 2017
  13. Phteven

    Phteven Member

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    So... back to the clutch, i stripped it down and found the clutch springs werent long enough but everything else was to spec. I have just put it all back together and now clutch wont engage. When i put it in gear it will give the usual clunk but the release the clutch and nothing

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