Kawasaki Ninja Service Manual: Spring Plate Free Play Adjustment

Kawasaki Ninja Service Manual / Clutch / Clutch / 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 steel plate(s) which brings the free play within the usable range.

Spring Plate Free Play Usable Range: 0.05 0.70 mm (0.002
0.028 in.)

Replace the following steel plate(s).

NOTE

Do not use the steel plate of 2.3 mm (0.090 in.) and 2.9 mm (0.114 in.) thickness at the same time.

Clutch Plate Assembly Length (Reference Information)

Assemble the following parts.

Clutch Hub [A] Spring Seat [B] Spring [C] Sub Clutch Hub [D] Sub Clutch Hub Bolts [E] New Friction Plates [F] Steel Plates [G] Spring Plate [H] Clutch Springs [I] Clutch Spring Holders [J] Clutch Spring Bolts [K]

Torque - Clutch Spring Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)

Measure the clutch plate assembly length [L].

Clutch Plate Assembly Length (Reference) 53.5 mm (2.11 in.)

Clutch Plate Assembly Length (Reference Information)

NOTE

The length of the clutch plate assembly changes by the steel plate thickness.

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 ...

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 ...

Other materials:

Idle Speed Control Valve Actuator Removal
NOTICE Never drop the idle speed control valve actuator especially on a hard surface. Such a shock to the actuator can damage it. Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Idle Speed Control Valve Actuator Retainer Screws [A] Idle Spe ...

Payload and Tire Pressure
Failure to maintain proper inflation pressures or observe payload limits for your tires may adversely affect handling and performance of yourmotorcycle and can result in loss of control. The maximum recommended load in addition to vehicle weight is 180 kg (397 lb), including rider, passenger, ...

Wheel/Tire Damage Inspection
Remove any imbedded stones [A] or other foreign particles [B] from tread. Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement. Visually inspect the wheel for cracks, cuts and dents ...