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:

Inner Tube Inspection
Visually inspect the inner tube [A]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is replaced. NOTICE If the inner tube is badly bent or creased, replace it. Excessive bending, followed by ...

Front Fork
The front fork operation and oil leakage should be checked in accordance with the Periodic Maintenance Chart. For various riding or load conditions the front fork can be adjusted for: Spring preload Rebound damping force Compression damping force WARNINGImproper fork leg adju ...

Upper Fairing Assembly Removal
Remove: Lower Fairings (see Lower Fairing Removal) Center Inner Fairing (see Center Inner Fairing Removal) Upper Inner Fairings (see Upper Inner Fairing Removal) Windshield (see Windshield Removal) Disconnect the front turn signal light lead connector [A] (both sides). Remove the bo ...