Kawasaki - Spring - 92145-1449

Mine is a 2001 Kawasaki Nomad 1500 V-twin. I didn't buy the parts to do the job myself but took it to a nearby shop that would do it for $65 an hour and it's a two hour job. They had impact wrenches and all the other proper tools and I don't so it was a no brainer to pass it on to them.

I knew I should order the parts myself because the shop isn't a Kawasaki dealership, I'd do the research to find better prices myself because they'd charge full retail, and I'd have all the parts required from the various sources required. I also got a K&N oil filter and 4 quarts of AmsOil V-twin synthetic because some oil would be lost during the spring change when the bike sits upright on a lift. It was time for a change and the guy said he'd be draining it before starting anyway so it made sense.

My problem was slipping clutch, although I only have 17,000 miles on the bike. The clutch which is never abused should give me at least 50,000 miles or maybe more. I didn't notice it at low speed and mild acceleration but any time I cranked up the juice, the slip was very noticeable in any gear. The Nomad is known for a weak clutch spring that loses it's "spring" and allows the symptoms of worn clutch plates although that's not really the problem. Vulcan clutch plates are VERY sturdy and don't wear easily from what I read.

After learning all this, I found a website that is renowned as THE major resource for DIY mechanics that I could copy and take to the shop for them to follow it and save a considerable amount of time compared to the Kawasaki process that requires taking off parts like the gas tank, fuel gauge sender module, and other stuff that isn't even close to related to the project. It's just time consuming riff-raff that boosts shop time billed for higher profits. The cool site from a rider who also did the work to his 2001 Kaw Nomad is:

http://www.gadgetjq.com/clutch_spring_replacement.htm

He also recommended putting in "Judges Washers" available from Robert (Judge) Oglesby because Kaw put an intentional clutch slip into the 1500cc Nomad spring system so launches are smoother but this isn't good for 2-up riding, MPG, or pulling a trailer. Kawasaki changed their spring system design on the 1600cc Nomad and started including washers similar to Judge's washers. And Kaw always had similar washers in the Mean Streak for performance launches. So since I was having it apart I got those too. They are only available for $33 from Judge and one other source, so the shop I was going to use wouldn't have even been aware of such a thing. Two big metal washers for $33 seems like a rip-off when you look at them but what they accomplish in the end is well worth the money so I highly advise them.

You'll notice that the Kaw clutch spring I ordered here is a stronger spring for a 2002 Kaw Mean Streak which is the preferred replacement for the wimpy Nomad spring and is 100% compatible.

The repair was done Wednesday 5/7/14 and I picked it up today 5/9/14 with high expectations. The shop guy rode it for 20 minutes and said it worked fine. I'm sure it did but it takes 45 minutes or so to make the symptoms show up. When I left the shop it was definitely better but still felt much the same - kind of slushy - which is not what I expected to experience. I got on I-75 for about 5 miles and when I got off to city streets the same slipping problem was back but not quite as bad. The new spring was helping but not solving the problem.

I had also read another Vulcan Nomad tip online that said if your clutch doesn't disengage properly that one should open the hydraulic clutch reservoir on the handlebars, soak all the fluid out (brake fluid actually) into a rag to empty the little tank, clean all the bottom of sludge, and clear two small holes in the bottom that get clogged with gunk by using a sharp object. My bike is 13 years old and I'd never known about that until recently or done it.

I did so and found the two holes. One had dark fluid sitting in it and one did not. I have a set of tools that I used to use for working on clarinets and flutes that are needle like and resemble dentist tartar cleaning tools except they aren't stainless steel. I put some towel around a very sharp pointed tool and cleared the fluid out of the one small hole so I could see in there better. I poked down into it several times and got some gunk out but it seemed to be open. I pressed the clutch lever in and didn't see anything happen except a little movement of the fluid way down in there - but I knew it had to be better than it was before. The second hole didn't do anything. So I started poking around in it looking for the small inlet port in the center. After about 4 pokes, the inlet shot fluid a foot in the air onto my glasses! After that, when I squeezed the clutch lever just a little a fine squirt of fluid would shoot up in the air at least a foot. Then I knew I had opened the ports properly and completely.

Parts used in this repair

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Total price:  $78.78

This item: Kawasaki SPRING (92145-1449) $37.63

Kawasaki GASKET, CLUTCH, COVER (11061-1081) $41.15

I used the mean streak clutch spring in my 97 vulcan classic 1500 due to the fact that it's a heavier duty spring. Stuck this in with a set of Barnett friction plates and Judge washers and wow what a difference! Took about a week and a half to get the part and everything went well.

Parts used in this repair

Total price:  $37.63

This item: Kawasaki SPRING (92145-1449) $37.63