KAWASAKI NINJA ZX12R clutch pack,oil and oil filter replacement

[@davespragg4570]

Hi. Having worked on these engines and my own bike you come across a few points that need special attention. The anti judder rings must go back in correctly and facing the right way round (flats and bevelled) you can't just pop them in and hope for the best . Stack height was not shown as this is important for the clutch to operate correctly. 57.6mm being the max end plate to end plate in the stack and if wrong they are adjusted by different thickness plates from oem stock at only £7 per plate. Oil and filter change. Several guys on the zx12r site myself included have filled the filter prior to refitting it to the engine. Good and bad in my book as a full filter and an empty oil gallery can cause an airlock and in a lot of cases will not budge Air compresses oil does not. Oil pumps are not good at suction only pressure . In this case you have to release the filter and allow a gap for the air to be expelled only then will the pressure be established. Only HALF fill the filter to avoid this air lock. This does happen quite a lot according to the guys on the zx12r site. To me I've NEVER tightened a filter up like as shown HAND TIGHT ONLY over 45 years on engines I've never had a leaker or one come loose. The hexagon on the end for ease of removal only. Well guys enjoy your zx12r ''s I certainly do, out of the 2 bikes I have zx9r and zx12r the 12r is invariably my chosen ride of the day. Same blue colour too. Ride safe.

[@wayno23]

Correct mate thanks for that. I realised after i replaced the clutch on mine, about the bevel & flat on the steels. They're still in there probably all mixed up , no issues so far. Which way does the bevel face , toward the gearbox or toward the brake lever ?

[@livingwithaninja3207]

Thank you for your message and sorry I've not been active on here for a good while. I did install the ring in the correct orientation as per the manual aswell as measuring the stack hight (I can't remember what measurement it was but was in spec). As for the oil filter I tightened to spec and I'm not sure about the air lock situation you speak of.i used information I gathered from groups and forums for the work and a manual..thank you once again and you to ride safe and enjoy my friend

[@wayno23]

@@livingwithaninja3207 no worries mate happy riding 😊 i am 👇 kzbin.info/www/bejne/h6DWm6aenKhgi7s

[@malamomanenga3359]

Hey my 03 zx12r bike ground the comp-clutch am struggling to get my clutch working, what's with that small steel plate should I call it a washer on the 6th steel plate?

[@markwat5958]

Lovely bike mate, you’ll enjoy getting to know her and taking care of her. I had a 03 B2H up until quite recently and it was a fantastic machine and never ever failed to bring a massive smile to my face every time I took her out. 2 bits of advice that will save you a lot of heart ache. 1) keep the 6 pot tokicos super clean, they work really well when you look after them but seize really easily if neglected. 2) when you need to change the plugs use the factory flexible spark plug spanner with the rubber insert, if it’s not in the tool kit, get a second hand kit off eBay with one in, the older KLX bikes have the same socket. The middle plugs are a real pain in the arse but use the flexi socket, it’s still a pig but you’ll get there. Enjoy

[@livingwithaninja3207]

Thanks for your advice and it is definitely taken on board,they do need a good going over. You will see how it goes on here. I think I may have that socket I'll have to check,the valve cover gasket needs replacing so it's a must anyway. Thanks again for watching and your help I do appreciate it 🏍️💨

[@retepbyers0294]

good vid, clear visual guide. i need to upgrade my A1 to a billet basket.

[@livingwithaninja3207]

Thanks man..yea I to would like the billet basket,I just can afford the set up ATM lol

[@drkstr7]

Which brand do you folks recommend? How much should I look to pay?

[@romanblackwelder2233]

Bro thank you for posting this video !! It will help me greatly. Also, nice shed haha

[@livingwithaninja3207]

💪🏻💪🏻😁

[@romanblackwelder4109]

so i have a problem what way does the needle bearing go and is it before or after washer also what way did you install the springs in clutch like curved out or in

[@malamomanenga3359]

Hey my 03 zx12r bike ground the comp-clutch am struggling to get my clutch working, what's with that small steel plate should I call it a washer on the 6th steel plate?

[@SL420Gaming]

Wicked vid bro

[@troydsouza3568]

Great Video Thanks, I Have A 2005 In Candy Plasma Blue And Its An Amazing Bike- Whats The Best Place To Buy Parts From? TIA

[@josevieira9596]

hello to everyone, especially the man of the great and valuable video ... but I confess to having a big doubt and that I have a lot to take, my friend you have a clutch kit for the model of the kawasaki zx12r from the year 2005 correct? The clutch of the model zx12 A does not take the two lubrication rings into the disc media nor does it use two friction discs with the smallest diameter. did you make the change to the clutch model kawasaki zx12 from the year 2002 ?? thanks if you can answer.

[@livingwithaninja3207]

After a good look I think you are right in what you say,if I understand you correctly. This boggles me tbh because the old clutch had the lube rings and plates,so I just assumed to replace ,like for like. But looking through a couple of manuals I see there is difference between them both. My bike is running ok,I think lol.what would this result in for my girl?

[@josevieira9596]

@@livingwithaninja3207 hello again, the result will be that the clutch of model A is more robust and firmer than model B, in the middle of the friction discs it has two washers, a friction disc plus a metal one with a larger diameter inside, in its model A no have these discs or washers, the fact is that these discs are more fragile because they are less resistant because they are smaller and as you know the zx12 model A has much more power than the zx12 model B, so there are differences between them. the clutch are not the same, different models have different powers. be careful that everything can go well but it can also go less well, when it comes to lubrication it is good, but for proper operation I think each model has the original parts. Hope this helps.

[@livingwithaninja3207]

@@josevieira9596 yes that makes sense thank you for letting me and others know.i will keep an eye on it and maybe take her to my local shop as he has 2 zx12rs.i will be sure to mention this in my next video. Thank you again for taking your time to comment 👍🏻👌🏻

[@josevieira9596]

@@livingwithaninja3207 ok, my friend i hope i gave a good help. there is another thing that many motorcyclists do not know and even good mechanics, that to change the clutch discs or complete clutch does not need to remove the oil from the engine, for that it is enough to leave the motorcycle a little more inclined or even on the rest of it and can remove the discs that no oil will come out, I hope I helped.

[@livingwithaninja3207]

@@josevieira9596 thank you,you have helped me with your insights.i will be sure to double triple check everything is ok.i am still confused how it is running ok

[@Ninjahall-12R]

Rebuilt the Engine on my '00 12R (crank and bearings, rods and bearings)... Without EVER opening an engine of any kind before...

[@livingwithaninja3207]

Props to you brother.they aren't the most beginner friendly machines lol.i don't know why I didnt comment back to you sooner/when I liked your comment..but here I am 👍🏻

[@drkstr7]

Great video, do you know where to get all the torque specs? How do you measure the stack height?

[@livingwithaninja3207]

I got all the specs with a pdf manual and I measured the stack hight with a micrometer/caliper

[@reggiekray270]

Same as my dads 03 plate crazy to see one with the lightning strikes in blue he’s had his since 2006 we have always called it his midlife crisis 🤣

[@livingwithaninja3207]

😂 I may be going through an early midlife crisis at 30 lol I hope he gets to ride her often

[@reggiekray270]

@@livingwithaninja3207 better getting the crisis over and done with lol he does get out on it very often he’s done around 40 thousand miles I’ve done around 10 thousand as a pillion on the back we toured in Europe twelve years ago for two months it was incredible and still to this day the only holiday I have ever been on I’ve always had a real soft spot for the ZX12R not really a fan of hayabusas there too fat 🤣

[@livingwithaninja3207]

@@reggiekray270 you guys been living the dream then?lol busas are to bubbly and bulbous for me,the styling on the 12 is far more superior..keep going for rides with each other n spend as much time as u can with it dad 💪🏻

[@reggiekray270]

@@livingwithaninja3207 it really is the dream busas still shift my dad test rode 1300 that was the same price as the kwak gave him sore wrists he said but fell in love with her straight away he wouldn’t part with it and said he wants to be buried with it 😂 he does all his own work and he’s changed every bolt he could for stainless he’s also got a 1993 zephyr 1100 first bike I went on at age nine it was amazing my dad had a bomber jacket on with me clinging on hit a 100mph I remember sliding back on the saddle and my dad pulling me back forward 🤣 amazing experience totally changed my life for the better

[@livingwithaninja3207]

I won't take the fact busas are fast for sure,they just don't have the appeal to me,it's nice to hear that being on the back and feeling the power had such a good impact on you,most cack themselves and hate bikes forever after that.lol

[@jaybee1892]

Hey how many of those spring type washers you have in between the plates ,are supposed to be in the clutch basket? Its funny I’ve changed my clutch many times before with no problems never taken spring/washers out. This time around my clutch cable has no tension at all. Watching your vid is the first time I’ve ever seen anyone have them or at least one in between the plates. Mine are both together in the rear of the basket behind all the plates. Im thinking maybe this is why my cable has so much slack

[@livingwithaninja3207]

Sorry for not being able to help.but there is a difference between the older and newer models,one has the rings the other doesn't.also as you see on the video I put the top cover plate that has the clutch springs in,the wrong way and had to rotate it slightly to have it fit snug.

[@malamomanenga3359]

Hey did u sort out urs? Same here plates and steel are perfect but no tension on the cable😢

[@jaybee1892]

You have to get the correct clutch plates anything else won’t fit, and it causes the cable to not have tension.

[@rickybarrett2854]

Did you measure your stack height or just hope for the best? Vital that the stack height is right on these bikes. What fibers did you use?

[@livingwithaninja3207]

Yea I measured the stack hight,I got OEM from a Kawasaki parts dealer.i was super paranoid about it tbh as it was my first time ever replacing a clutch on any bike. She rides ok as far as changing gear/going to neutral got no drag or slip on the clutch either.

[@griffinhaven42]

When you take it apart you speed up and I can't tell if you have two rings at the 5th wide outside diameter ring and what is at the end with the wide outside diameter? A flat and a beveled? Does this mean both wide diameter rings have two inside rings?

[@griffinhaven42]

Judder springs

[@livingwithaninja3207]

Yes I'm sure both the wider plates have two judder springs with the flat one first (toward the rider on the bike) and the beveled ring after with the narrow part of the beveled ring also pointing towards the rider.i hope that helps

[@shefanie100]

I see 3 rings with my motorcycle I see 4 do you have the order of the rings ?, Kawasaki manual is not it.

[@livingwithaninja3207]

Sorry I don't quite understand your question.

[@mikethebike6825]

You just got to love them ninjas 😁

[@livingwithaninja3207]

I agree.big up the ninja fam!!✊🏻💪🏻

[@kentuckynightrider725]

Is yours a 00 or 01? I’ve got a 00 that I’m having trouble with. And midways of your clutch is that jetter spring flat or curved? And in the back of the clutch is there a flat and a curved jetter spring? My shifter isn’t wanting to return ever since I’ve tried messing with my clutch now.

[@livingwithaninja3207]

As I am aware 01 but registered as 02 in UK..sorry I've been absent I'm looking on putting some more vids up soon hopefully I've been very busy and not on the bike..but there is 2 sets of washer plate things in pairs.one is flat and the other is like a 'cone' shape but very slight if that makes sense. lol.one pair is at the back of the stack with the first clutch plate over it the other is about half way with the friction plate both got bigfer holes for the washers to sit in..the 'coned' shaped washers should have the more narrow part facing the engine,so the outer edge of the cone washer is facing you..it's hard to explain but I hope that helps l.let me know and I'll explain on the next video mate

[@josevieira9596]

the model zx12 from year 00 is the same as from 01 so from 02 is that it is already the second model that this model ends in 2006

[@johnnyaroha4246]

What year bike mate?

[@sergioortiz9868]

Hey man I got my 05 zx12 .. You habe any judder springs ?

[@livingwithaninja3207]

No brother I dont.how is she treating you

[@clintoncloete3260]

Bro im so done with my Zx12R even after replacing the clutch kit it still creeps in 1st gear even when engaging the clutch.

[@joeshow8815]

I guess all the ones that gave this video a like , already know how to rebuild a clutch and came here just to hear the music. I don't know how to rebuild it and for one, rather than hearing music I would prefer to hear what is that green fluid you put the clutch rings into.

[@livingwithaninja3207]

Lol I'm happy the music pleased you..and that green fluid is motor oil.its recommend to soak the plates for at least a couple of hours but over night is best

[@joeshow8815]

@@livingwithaninja3207 the music annoyed me

[@delicadamentedespertando1807]

Congratulations

[@livingwithaninja3207]

😁💪

[@clausfkvist]

Great have same model/color 48000 km

[@livingwithaninja3207]

They are sweet.i wasn't extremely happy about the colour but now I love it.😁💪🏻

[@markjones464]

Just run in , I sold my 12r , with 93,000 km , changed oil and filter Every 7000km , oil is Cheap compared To Engine rebuild.

[@Ninjahall-12R]

Easy fix...

[@jeffreybrown4657]

M mm😊

[@slitherbuzz1028]

Hi chub

[@livingwithaninja3207]

💪🏻💪🏻fam