Kawasaki Ninja Service Manual: Clutch Installation

Kawasaki Ninja Service Manual / Clutch / Clutch / Clutch Installation

Clutch Installation


Fit the holes [B] and projections [C].

Engage the clutch housing gear and the crankshaft primary gear.

Clutch Installation


Turn the stepped side [C] of the spacer to outside.

Clutch Installation


If the sub clutch hub bolts were removed, install them as follows.

Apply a non-permanent locking agent to the threads of the sub clutch hub bolts, and tighten them.

Torque - Sub Clutch Hub Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Clutch Installation


First Torque Limiter Spring [A] Tang [B]

Clutch Installation


Second Torque Limiter Spring [A] Tang [B]

Clutch Installation


Third Torque Limiter Spring [A] Tang [B]

Clutch Installation


Fourth Torque Limiter Spring [A] Tang [B]

Clutch Installation


Special Tool - Clutch Holder: 57001-1243

Torque - Clutch Hub Nut: 130 N·m (13.3 kgf·m, 96 ft·lb)

Clutch Installation


NOTE

Clutch Installation


NOTICE

If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each plate to avoid clutch plate seizure.

Clutch Installation


Clutch Installation


Clutch Installation


Clutch Removal
Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs (with Clutch Spring Holders) Clutch Spring Plate [B] Pusher [C] Remove: Friction Plates ...

Spring Plate Free Play Measurement
Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spo ...

Other materials:

Front Master Cylinder Removal
Remove the reservoir mounting bolt and nut [A]. Unscrew the banjo bolt [A] and disconnect the brake hose from the master cylinder (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). Unscrew the clamp bolts [B], and take off themaster cylinder as an assembl ...

Engine Removal
Support the rear part of the swingarm with a stand. Squeeze the brake lever slowly and hold it with a band [A]. WARNINGMotorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine. NOTICE Be sure ...

Brake Hose and Pipe Replacement
NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Brake Hose Fitting Bolt [A] Brake Hose Banjo Bolts [B] Bolt [C] Clamp ...