Hey Hub!!

Just ordered a 16t for my beast and wanted to know is there any special steps I need to take to put this on, just looking at it, it will not be as easy as the gixxer was.

Thanks for any help.

Round off that spline nut-yer HISTORY.Just a couple of slips with that breaker bar-OOOPS.It won't take much to make that nut UNWORKABLE with any tool(not to mention damaging yer bike by hittin it)That square part of the nut-Don't damage that by trying to use it to loosen the nut.The nut only has about a 16th or so edge for holding a socket on there.Better get it right THE FIRST TIME ya apply the breaking force.You know,I did this myself-twice-.It was worth EVERY DOLLAR to buy an electric impact wrench.Mine is rated at 350 lbs.It's a KOBALT-bought it at Lowe's.$130.00.Worked perfectly.You're gonna need a DEEP socket-1/2" drive,1 and 3/8ths SAE.You won't find yer Kawasaki socket for this in a parts store.It'll be just SLIGHTLY BIGGER than the Kawi one,but it will work just fine.(I think it's a 35 mm).I couldn't find one. Have someone hold the rear brake for ya when ya go to bust er loose(or tighten)She's NOT gonna break loose instantly,so KEEP THAT PRESSURE ON THE IMPACT GUN STRAIGHT IN ON THE NUT.It may take a couple of tries.Just stay with it and don't stop cranking-it will break free.Make sure yer turning the nut COUNTERCLOCKWISE!!!!Before ya start loosening,make sure that washer there is COMPLETELY FOLDED DOWN FLAT against the housing there(use a sharp flattip screwdriver to pry it down).If it isn't,that socket won't grab enough to get the necessary bite on the nut.You don't want to botch this job!!!(wasn't tryin to hijack yer response HUB-just tryin to save this gent a BIG HEADACHE if he gets it wrong.And it can go wrong very easily with a side force breaker bar). If I were you(and I was)-I'd number those clutch cover and slave cylinder bolts as you take em out.You're gonna find out that they are DIFFERENT LENGTHS.You know,make a little diagram on some paper there and set em up just like you take em out.That black plastic washer in the slave cylinder housing-make sure ya get that in there right.And watch your torque when retightening those bolts.The case is "SOFT".Crisscross the tightening sequence and make sure the cover is sitting on there FLAT against the case.(don't forget to make sure that little hose is routed BEHIND the cover and down through the cutout in the cover).Loosen yer rear wheel and give yerself all the slack you can-you're gonna need it when you remove that sprocket.You may have to pull the chain AND sprocket out TOGETHER-I had to.The chain guide there will BEND out away from the housing by removing the upper and lower bolts,no need to pull it all the way off. The sprocket did slide off the spline shaft WITH THE CHAIN AROUND IT just enough to get it off the shaft.Just took some patience and care sliding it off(the chain will flex enough to pull em out).You can get the sprocket moving by sliding a large flattip screwdriver behind it and giving it a nudge.Make sure that washer is back on the spline nut and folded up against it like it was.DON'T remove ANY CLUTCH LINE FITTINGS.Leave em connected.Just pull the Clutch Lever in against the grip,and tape it there.(before you remove the slave!)You won't lose any fluid if ya do it that way.I'd say....Spend the bucks and GET THE IMPACT!!!!You WON'T regret it! Just a word of caution...use ONLY a hand held socket wrench when tightening those cover and slave bolts! And don't forget to pump yer clutch lever when yer all done!!!! (Sorry,I forgot you did this on yer Gixxer!(my bad).Take care!!!

* Last updated by: blue07 on 5/21/2009 @ 6:22 PM *

Thanks guys, great info

Ya HUB-I was hopin you wouldn't get offended.Thanks Bro-Ride safe there-Have fun!!

everybody has their own way of popping the nut loose so here is mine. Tighten the chain tite then have someone push the rear brake pedal down so brake/chain keep the front sprocket from moving at all. My electric impact will pop the nut off because the sprocket does not move to lessen the impact action.

There are many ways that work but that is mine.

Wish I'd said that!!!!(instead,I had to write a book)!

* Last updated by: blue07 on 6/12/2009 @ 9:46 PM *