Judges 1500 & 1600 Clutch-spring-washers instructions.

Refer to the Clutch Spring Replacement instructions for the disassembly instructions.

The washers in this kit are to be used with ALL other O.E. clutch parts.

(EDITOR NOTE: Gadget's Opinion here is based upon use of the old weaker spring and single holder. With new washer and double holders I don't think this is the case any longer.) When installed properly, the clutch-spring-life will be (at LEAST), doubled!! You will also notice a more positive clutch “feel”, quicker “roll-on” acceleration and in many cases, a smoother shifting transmission.

This assembly will increase rear wheel traction. Make sure to match engine speed (RPMs) to ground speed as you down-shift. If not, the rear wheel can lock and skid, causing loss of control!! This kit will make the clutch work similar to the “old-style” pre-slipper clutches that are on most bikes, including the VN800 and VN2000.

USE CAUTION IF YOU ARE A NEW Rider!!

• The larger I.D. washer is installed on the “holder” BEFORE the spring is installed.
• NOW install the spring against the washer. The washer will carry the load and the wear.
• The smaller I.D. washer is installed on the lower half of the “holder” BEFORE the 3 limiter springs are installed.
• Now install the 3 limiter springs.

  Use a “sticky” grease to “glue” ALL parts together during the install, or they WILL fall off of the “holder” and be damaged while tightening the 27mm nut! !Do not use “magic” or “special” grease. It must be able to melt away as the oil heats up!

The assembly MUST LOOK LIKE THIS when installed on the holder ( from engine side out)

*(LATE 1500’s and 1600’s). If you have the factory installed “indexing-washer” install it as it was, between the spring and the large washer. It may be eliminated ONLY if the M/Streak spring is used WITH the washers. I do NOT have data on the life expectancy of the spring, when eliminating the indexing washer. (The Late models have had the “holder” back-cut the thickness of the indexing washer.)

1600 riders….I NEED DATA! I’m having more and more calls for the 1600 (& late 1500 kits)

For 2-up riding, performance or towing, I highly recommend using the Mean Streak spring, (Kawasaki part # 92145-1449). A slight increase clutch-lever-pull may be noticed!

If you have removed the clutch plates to check them, make SURE that the last plate installed is in a “short-slot” of the clutch-basket, NOT the same “slots” as all other plates or your clutch will begin to slip after just a few miles! Make sure that you align the oil-pump-gear WITH the clutch-basket-gear or damage to the gear may occur when the 27mm nut is torqued or on start up! Rev. 8 / 26 / 08