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:

Coolant Level Inspection
Situate the motorcycle so that it is perpendicular to the ground. Check the coolant level through the coolant level gauge on the reserve tank located to the left of the engine. The coolant level should be between the “F” (Full) and “L” (Low) level lines. A. Reserve Ta ...

Brake Pedal Installation
Apply grease to the brake pedal pivot shaft [A]. Install: Washers [B] Brake Pedal [C] Apply a non-permanent locking agent to the threads of the brake pedal mounting bolt [D], and tighten it. Torque - Brake Pedal Mounting Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) Install the re ...

Throttle Body Assy Installation
Apply a thin coat of grease to the throttle cable lower ends. Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley. Install the clamp [C] securely. Install the throttle body assy holder clamp bolt heads [A] outside as shown in the figure. ...