Kawasaki Ninja Service Manual: Clutch Plate Warp Inspection

Kawasaki Ninja Service Manual / Clutch / Clutch / Clutch Plate Warp Inspection

Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp.

If any plate is warped over the service limit, replace it with a new one.

Clutch Plate Warp Inspection

Friction and Steel Plate Warp

Standard: 0.15 mm (0.0059 in.) or less

Service Limit: 0.3 mm (0.012 in.)

Clutch Plate, Wear, Damage Inspection

Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. Measure the thickness of each friction plate [A] at several points. If any ...

Clutch Spring Free Length Measurement

Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 43.5 mm (1.71 in.) Service Limit: ...

Other materials:

Fuel Pump Operating Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove: Fuel Tank Bolts (see Fuel Tank Removal) Fuel Tank Bracket Bolts (see Fuel Tank Removal) Disconnect the fuel pump lead connector and connect the harness adapter [A] between these connectors as shown i ...

Air Switching Valve (Service Code 64)
Air Switching Valve Removal/Installation Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection Refer to the Air Switching Valve Unit Test in the Electrical System chapter. If the air switching valve [A] is normal, check ...

Battery Charging
Remove the battery from the motorcycle (see Battery Removal). Attach the leads from the charger and charge the battery at a rate (amperage x hours) that is indicated on the battery. If it is not possible to read the rate, charge the battery at an amperage that is about 1/10th of the ...