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:

Subthrottle Valve Actuator Resistance Inspection
Turn the ignition switch to OFF. Disconnect the subthrottle valve actuator connector [A]. Connect a digital meter to the subthrottle valve actuator connector [A]. Measure the subthrottle valve actuator resistance. Subthrottle Valve Actuator Resistance Connections: Y/BK lead [1 ...

Intake Air Pressure Sensor #2 Installation
NOTE The intake air pressure sensor #2 is the same part as the intake air pressure sensor #1. Installation is basically the reverse of removal. Position the intake air pressure sensor #2 [A] between the projections [B] on the rubber damper. Install the rubber damper [A] on the brac ...

DFI Servicing Precautions
There are a number of important precautions that should be followed servicing the DFI system. This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. Do not reverse the battery ...