ATHENA Clutch Friction Plate Kit + cover gasket for KAWASAKI KX 500 1988-2004

The ATHENA P40230065 clutch friction plate kit is designed for KAWASAKI KX 500 from 1988 to 2004. The friction plates transmit engine torque to the gearbox by gripping against the steel plates. As they wear, they get thinner: the clutch slips, overheats and the bike loses traction.

Specifications

• Brand: ATHENA
• Manufacturer part number: P40230065
• EAN code: 8052780272650
• Weight: 380 g
• Engine: 2-stroke

When to replace it?

• Revs rise but the bike doesn't pick up speed (slipping), especially in the higher gears.
• Engagement point that wanders, clutch that judders or smells burnt.
• Plates below the minimum thickness given in the manual.

Measure plate thickness with a vernier caliper at every clutch check and replace the plates once they're below the minimum in the manual, or as soon as they slip.

Fitting tips

1. Soak the new friction plates in gearbox oil before fitting them.
2. Check the steel plates (flatness, blueing) and the clutch springs; replace them if necessary.
3. Make sure the basket fingers aren't notched: if they are, the clutch will snag.
4. Reassemble in the original order, tighten to the manufacturer's torque and close up with a new clutch cover gasket.

Why ATHENA?

Athena, an Italian company founded in 1973 near Vicenza, designs gaskets, pistons and cylinder kits for motorcycles. An OEM supplier to KTM, Ducati, Fantic, Piaggio and Triumph and a partner of the MXGP world championship, it develops its parts on the test bench and on the track with racing teams.

Spare parts and items to plan

• Clutch steel plates : TECNIUM · ATHENA
• Clutch springs : EBC · PROX
• Clutch cover gasket : CENTAURO · ATHENA
• Gearbox oil : LIQUI MOLY 10W30 1 L · LIQUI MOLY 80W 500 ml

Frequently asked questions

Should the steel plates be replaced at the same time?
If they're blued, warped or marked, yes: fit new steel plates. If not, check them and keep them.

Is the cover gasket included?
Yes: this kit includes the clutch cover gasket.

Compatibility

Check the exact model and year of your bike in the list below before ordering.

Fits:
KAWASAKI KX 500 2004
KAWASAKI KX 500 2003
KAWASAKI KX 500 2002
KAWASAKI KX 500 2001
KAWASAKI KX 500 2000
KAWASAKI KX 500 1999
KAWASAKI KX 500 1998
KAWASAKI KX 500 1997
KAWASAKI KX 500 1996
KAWASAKI KX 500 1995
KAWASAKI KX 500 1994
KAWASAKI KX 500 1993
KAWASAKI KX 500 1992
KAWASAKI KX 500 1991
KAWASAKI KX 500 1990
KAWASAKI KX 500 1989
KAWASAKI KX 500 1988