Kawasaki Ninja Service Manual: Clutch Plate, Wear, Damage Inspection

Kawasaki Ninja Service Manual / Clutch / Clutch / 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 plates show signs of damage, or if they have worn past the service limit, replace them with new ones.

Clutch Plate, Wear, Damage Inspection

Friction Plate Thickness

Standard: 2.72 2.88 mm
(0.107 0.113 in.)

Service Limit: 2.5 mm (0.098 in.)

Spring Plate Free Play Adjustment

NOTE The free play adjustment is performed by replacing the steel plate(s). Measure the clutch spring plate free play (see Clutch Spring Plate Free Play Measurement), and then replace the st ...

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 ...

Other materials:

Wheel Bearing Damage Inspection
Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter). Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 Turn the handlebar all the way to the right or left. Inspect the roughness of the front wheel bearing by moving [A] ...

Air Cleaner Housing Removal
Remove the fuel tank (see Fuel Tank Removal). Disconnect the secondary fuel hose [A] from the delivery pipe of the nozzle assy [B] (see Fuel Hose Replacement in the Periodic Maintenance chapter). Disconnect the secondary fuel injector connectors [C]. Free the lead from the grooves [D]. ...

Radiator and Cooling Fan
Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a stream of low-pressure water. WARNINGThe cooling fan spins at high speed and can cause serious injuries. Keep your hands and clothing away from the cooling fan blades at all times. ...