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:

Outline
When a problem occurs with DFI system, the warning indicator light (LED) [A] and FI warning symbol [B] goes on to alert the rider. In addition, the condition of the problem is stored in the memory of the ECU. For models equipped with an immobilizer system, the warning indicator light (LED) and ...

Footpeg
Footpeg Height Adjustment The front footpeg can be adjusted within 2 positions in height to suit the rider’s preference. Footpeg [A] Bolts [B] Bolt Holes [C] Footpeg Position 1 [D] Footpeg Position 2 [E] Remove the bolts [A]. Adjust the footpeg height. NOTE In ...

Rear Sprocket Warp Inspection
Raise the rear wheel off the ground with the stand so that it will turn freely. Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown in the figure, and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the highest and lowest di ...