new clutch = new problem please help

[degreaser]

oh and another thing comes to my mind on those 3 limiter springs, tell him that on reinstall they go on like this )()
engine side )() clutch spring nut
all 3 washers are curved

[cactusjack]

Sadly, this is what can happen when you trust others to perform work. If you can't do the work yourself, then you don't have many options.

Something nobody else has mentioned is the oil. What kind of oil is in the crankcase? Since it also lubes the clutch you can't use any oils marked "energy conserving". The friction modifiers are too slippery and it reduces the ability of the clutch to grab. Just something to chew on.

If I had to guess, I'd say the problem is a weak clutch spring and/or incorrect reassembly of the clutch. I'd replace the spring with a Barnett MT-25 since it has to be taken apart anyway, and use the Kawasaki shop manual or at least Gadget's page for proper reassembly. It isn't a very complicated clutch system.

Good luck!

[degreaser]

Here's a picture of those 3 limiter springs
http://img832.imageshack.us/img832/9...geswashers.jpg

in the picture is washer #1 and washer #2, those are 2 Judge's washers, the other 3 top washers with lots of grease on them is the 3 limiter washers

[degreaser]

ok the Barnett spring is mentioned, which brings me to the spring, the stock spring will be thinner then the 2003 P2 MeanStreak spring, and the MeanStreak spring is thinner then the Barnett, I install a MeanStreak spring and clutch lever pull is just a tad stiffer than stock, while the mechanic is in there why not suggest installing either a new MeanStreak spring or a Barnett, I replaced my spring at 33,000 miles

[degreaser]

Here's another read on clutch replacement, It might help to go thru it all so that if you ever get to the shop and see your bike apart you might recognize the parts.

http://home.insightbb.com/~franova/N-Clutch-Replace.htm

[degreaser]

oh I have another thought, you have a 2001, you might want to consider getting and installing Judge's washers, because your G3 has no stock star washer which Kawasaki introduced in the 2004 model year, Kawasaki saw what Judge was making and designed their own washer that does what Judge's washers do which is to put a washer between the outside clutch spring teeth and the holder grove

[degreaser]

Here's a link to ron ayers parts on the clutch, notice part 13280A Kawasaki Part Number 13280-1306 which is the star shaped washer which Kawasaki designed to replace Judge's washer, you can go either 2 ways, either install judge's washers or install both the star washer and holder, part #'s 13280-1306 & 13280-1307 along with a 2003 P2 Meanstreak or Barnett clutch spring

http://www.ronayers.com/Fiche/TypeID...6/Group/Clutch

[rickyboy]

Jay, you're probably on your way to the shop and fixing the bike now ....but as a lot have suggested and I said from the get go,...and as Scott/CJ suggested, you'll have the casing off and everything apart, so grab a Barnett MT-25. I and those I know that have gone this route have no regrets on going with the Barnett spring. Good luck...I hope you printed out the gadget page and the other art. someone linked you up with.
I encourage you to learn to do what you can, to do your own repairs. Borrow someones/a friends garage and buy a shop manual off eBay along with some basic tools and learn to do the repairs. You'll save money, know exactly what has been done to the bike, and have some fun and self satisfaction of doing it yourself. You can do it !!!
Let us know how you make out with the clutch and what was wrong. Any of us who responded to your plea for help surely want to know.
Can I call you "Shirley"???

[degreaser]

by the way, I intalled both Judge's washers along with the stock Kawasaki star washer part 13280-1306 along with a 2003 meanstreak spring and all is fine

[crazyjay1978]

W definitely will keep everyone posted I will be heading there in a hour or 2 thank you for everyone's help!

[crazyjay1978]

Well just got the bike back home! The conclusion is the nut backed off . He appoligized a hundred times and doesn't under stand why he said he used a impact wrench and torqued it so this time he used a new nut and the clutch feels better then when i picked it up the first time I couldn't get a new spring plate for a few days cuz no one had it in stock so that will be a project for another day . Thank you for everyone's help today

[ringadingh]

That was an easy fix, these bikes are usually very dependable and foolproof.

[rickyboy]

glad it was quick easy fix for you.
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