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:

Transmission Shaft Assembly
Apply molybdenum disulfide oil solution to the sliding surfaces of the gears and shafts. Install the gears and the gear bushings [A] with their holes [B] aligned. Replace any circlips removed with new ones. Install the circlips [A] so that the opening [B] of it is aligned with ...

Release Shaft Installation
Apply grease to the oil seal lips on the upper ridge of the clutch cover. Apply engine oil to the needle bearings in the hole of the clutch cover. Applymolybdenum disulfide grease to the pusher-holding portion [A] on the release shaft. Install the washer [B] and spring [C]. ...

ECU Communication Error (Service Code 39)
ECU Communication Line Inspection When the data is not sent from the ECU to the meter unit for more than about 10 seconds, the service code 39 is displayed. The data is sent through the CAN communication line. The service code 39 is detected with the meter unit. When the user mode, this commun ...