The holding nut on my clutch release screw appears to be stripped. I'm not sure if it is the nut or the threads in the case yet. I have not yet pulled the cover off. Has any one ever replaced this or know what it looks like on the inside? The screw will turn along with the nut and never tighten. They seemed to have been seized together and it was a son of a to get it free. Nice of them to use a nice soft BRASS screw. Anyway the clutch feels as though it is not releasing correctly and I know I need to adjust it properly but am unable to do so since the holding nut won't tighten. Anyone have any words of wisdom on this or ever done it before? Can the cover be retapped or will I have to replace the whole cover(hope not)? If it has to be replaced, anyone know how much this engine cover costs? Is this quite a chore or a fairly simple procedure to replace the screw and nut?

 

its really easy to replace the screw, i did it on my 97 in a matter of minuits. if i remember correctly the screw goes through an oil seal, so you dont need to worry about retapping the cover.
just drain the oil, remove the 8 or so cap screws,and your there. check the oil screen while you have the cover off. i will check my svc manual today to find out if there is any thing else that will help. your dealer will probably have to order the screw and seal for you anyway.

 

Thanks for the info. mster! Doesn't sound bad at all. I really need to get myself a service manual. BTW, if my oil screen is clogged what do I need to clean it with? Thanks again.

 

clean it with compressed air or a solvent its a metal screen so it should go easy. carfull not to pull the rubber seal off when you remove it , they should come out together as one piece.
seems i may be wrong about the case not being threaded. i think it migt be, now that i look at the svc.manual again. (it only shows an exploded view. i would remove the cover and see if you can take it out from the other side .
there is an o ring that acts as a seal on the outside,-its under the washer.
a great source for o0em parts is KAWASAKI DISCOUNT PARTS WAREHOUSE 1-800-448-8611
they sell for 1/ to 1/3 what local dealers do